Electric Motor Control Basics: - A Compilation of Our Most Popular White Papers

Electric Motor Control Basics
— a compilation of our most popular white papers

Contents
3. Industrial Control Basics: Part 1, Contactors
18. Industrial Control Basics: Part 2, Overload Relays
29. Industrial Control Basics: Part 3, Starters
46. The Benefits of Type E/F Motor Protection Circuit Breakers
53. Basic Pump Control: Three Phase DOL Starter Control of an Electric Pump
54. Applying Motor Control in a Wastewater Application
72. NEMA vs IEC Motor Controls
86. Understanding IP Ratings
02
Industrial Control Basics:
Part 1, Contactors
Industrial Control
Basics:
Part 1, Contactors
Introduction
Industrial Control
A contactor is an electrical device which is used for switching an electrical circuit on or Basics: Part 2,
Overload Relays
off. It is considered to be a special type of relay. However, the basic difference between
the relay and contactor is that the contactor is used in applications with higher current
Industrial Control
carrying capacity, whereas the relay is used for lower current applications. Contactors Basics: Part 3,
can be field mounted easily and are compact in size. Generally, these electrical devices Starters
feature multiple contacts. These contacts are in most cases normally open and provide
The Benefits of Type E/F
operating power to the load when the contactor coil is energized. Contactors are most Motor Protection
commonly used for controlling electric motors. Circuit Breakers
There are various types of contactors, and each type has its own set of features, Basic Pump Control:
Three Phase DOL Starter
capabilities, and applications. Contactors can break current over a wide range of Control of an Electric Pump
currents, from a few amperes to thousands of amperes, and voltages from 24 VDC
to thousands of volts. In addition, these electrical devices come in varying sizes, from Applying Motor Control
in a Wastewater
hand-held dimensions to sizes measuring a meter or yard on one side (approximately). Application
The most common application area of the contactor is high-current load. Contactors NEMA vs IEC Motor
are known for their capability to handle currents of over 5000 amperes and high power Controls
over 100 kW. Heavy motor currents produce arcs when being interrupted. These arcs
Understanding
can be reduced and controlled using a contactor. IP Ratings
03
Industrial Control Basics: Part 1, Contactors
Contactor Components Industrial Control

Basics:
The following three are crucial components of the contactor: Part 1, Contactors
1. Coil or Electromagnet: This is the most crucial component of a contactor. The

Industrial Control
driving force that is required to close the contacts is provided by the coil or Basics: Part 2,
electromagnet of the contactor. The coil or electromagnet and contacts are Overload Relays
protected by an enclosure.
Industrial Control
2. Enclosure: Just like the enclosures used in any other application, contactors also Basics: Part 3,
feature an enclosure, which provides insulation and protection from personnel Starters
touching the contacts. The protective enclosure is made from different materials,
such as polycarbonate, polyester, Nylon 6, Bakelite, thermosetting plastics, and The Benefits of Type E/F
Motor Protection
others. Generally, the open-frame contactor features an additional enclosure, Circuit Breakers
which protects the device from bad weather, hazards of explosion, dust, and oil.
3. Contacts: This is yet another important component of this electrical device. The Basic Pump Control:
current carrying task of the contactor is done by the contacts. There are different Control of an Electric Pump
types of contacts in a contactor namely, contact springs, auxiliary contacts, and
power contacts. Each type of contact has an individual role to play. Applying Motor Control
in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
04
How the Contactor Operates Industrial Control

Basics:
Operating Principle of a Contactor: The current passing through the contactor excites Part 1, Contactors
the electromagnet. The excited electromagnet produces a magnetic field, causing the
contactor core to move the armature. A normally closed (NC) contact completes the Industrial Control
circuit between the fixed contacts and the moving contacts. This permits the current Basics: Part 2,
Overload Relays
to pass through these contacts to the load. When current is removed, the coil is de-
energized and opens the circuit. The contacts of the contactors are known for their
Industrial Control
rapid open and close action. Basics: Part 3,
Starters
Working on a Contactor
Motor Protection
Circuit Breakers
Basic Pump Control:

Control of an Electric Pump
Applying Motor Control

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
05
Different Types of Contactor Devices Industrial Control

Basics:
1. Knife Blade Switch Part 1, Contactors
Knife Blade Switch
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
The knife blade switch was used earlier in the late 1800’s. It was probably the first Basic Pump Control:
ever contactor that was used to control (start or stop) electric motors. The switch Three Phase DOL Starter
consisted of a metal strip, which would drop onto a contact. This switch had a lever
for pulling the switch down or pushing it up. Back then, one had to level the knife Applying Motor Control
blade switch into the closed position by standing next to it. in a Wastewater
Application
However, there was a problem with this method of switching. This method caused
NEMA vs IEC Motor
the contacts to wear out quickly, since it was difficult to manually open and close Controls
the switch fast enough to avoid arcing. As a result of this, the soft copper switches
underwent corrosion, which further made them vulnerable to moisture and dirt. Understanding
IP Ratings
Over the years, the size of the motors increased which further created the need for
larger currents to operate them. This created potential physical danger to operate
such high current carrying switches, thus leading to a serious safety concern.
06
In spite of doing several mechanical improvements, the knife blade switch couldn’t be Industrial Control
Basics:
fully developed due to the pertaining problems and risks of dangerous operation and
Part 1, Contactors
short life of the contacts.
Industrial Control
2. Manual Controller Basics: Part 2,
Overload Relays
Since the knife blade switch became potentially dangerous to use, engineers came up
with another contactor device, which offered a number of features that were missing Industrial Control
in the knife blade switch. This device was referred to as a manual controller. These Basics: Part 3,
Starters
features included:
• Safe to operate
• Non-exposed unit, which is properly encased Motor Protection
• Physically smaller size Circuit Breakers
• Single break contacts replaced with double break contacts

Basic Pump Control:
Double Break Contactors Control of an Electric Pump

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
07
As their name implies, double break contacts can open the circuit in two places at Industrial Control
Basics:
the same time. Thus, even in smaller spaces, it allows you to work with more current.
Part 1, Contactors
Double break contacts divide the connection in such a way that it forms two sets of
contacts.
Industrial Control
Basics: Part 2,
The switch or button of the manual controller is not operated remotely and is Overload Relays
attached to the controller physically.

Industrial Control
Basics: Part 3,
The power circuit is engaged once the manual controller is activated by an operator. Starters
Once activated, it carries the electricity to the load. Soon, manual contactors replaced
knife blade switches completely, and even today different variations of these types of The Benefits of Type E/F
Motor Protection
contactors are being used. Circuit Breakers
Basic Pump Control:

3. Magnetic Contactor Three Phase DOL Starter
The magnetic contactor does not require human intervention and operates
electromechanically. This is one of the most advanced designs of a contactor, which
can be operated remotely. Thus, it helps eliminate the risks involved in operating it in a Wastewater
manually and putting operating personnel in potential danger. Only a small amount Application
of control current is required by the magnetic contactor to open or close the circuit.
This is the most common type of contactor used in industrial control applications. NEMA vs IEC Motor
Controls
Understanding
IP Ratings
08
The Life Expectancy of a Contactor or Contact Life Industrial Control

Basics:
The life expectancy of a contactor or its “contact life” is one of the biggest concerns of Part 1, Contactors
a user. It is natural that the contacts are being opened and closed more frequently, the
life of the contactor will decrease. The opening and closing of the contacts create an Industrial Control
electric arc, which generates additional heat. The continued production of these arcs Basics: Part 2,
Overload Relays
can damage the contact surface.
Industrial Control
Furthermore, the electrical arcs cause pitting and burn marks, which eventually blacken Basics: Part 3,
Starters
the contacts. However, the black deposit or oxide on the contacts make them even
more capable of conducting electricity efficiently. Nevertheless, when the contacts get
worn out and corroded to a large extent, then it is necessary to replace them. Motor Protection
Circuit Breakers
Thus, the faster the contact closes, the quicker the arc extinguishes. This in turn helps
Basic Pump Control:
to increase the life of the contact. The latest contactor versions are designed in such Three Phase DOL Starter
a way that they close very quickly and energetically. This causes them to slam against Control of an Electric Pump
each other and produce a bouncing action as they rebound. This action is known as
contact bounce. The contact bounce phenomenon creates a secondary arc. It is not only Applying Motor Control
in a Wastewater
important to close the contacts quickly, but also to reduce the contact bouncing. This Application
helps reduce wear and secondary arcing.
NEMA vs IEC Motor
Controls
Understanding
IP Ratings
09
NEMA vs IEC Industrial Control

Basics:
There are two standards for contactors: NEMA and IEC. Part 1, Contactors
NEMA (National Electrical Manufacturers Association) is the largest trade association

Industrial Control
of electrical equipment manufacturers in the United States. NEMA encouraged Basics: Part 2,
Overload Relays
manufacturers to standardize on frame sizes to allow users to confidently specify,
purchase, and install electrical components from different manufacturers without a lot
Industrial Control
of hassle and cross-referencing. NEMA contactors also are designed with safety factors Basics: Part 3,
that go beyond design ratings (oversized), up to as much as 25%. NEMA is primarily a Starters
North American Standard.
Motor Protection
NEMA contactors for low-voltage motors (less than 1,000 volts) are rated according Circuit Breakers
to NEMA size, which gives a maximum continuous current rating and a rating by
horsepower for attached induction motors. NEMA standard contactor sizes are Basic Pump Control:
designated 00, 0, 1, 2, 3 to 9. Control of an Electric Pump
IEC (International Electrotechnical Commission) is a global standard. IEC contactors Applying Motor Control
are not oversized. They are smaller than NEMA contactors and less expensive. The in a Wastewater
Application
range of sizes offered by manufacturers is more numerous than the ten NEMA
standards. As such, they are more specific to a given application and are specified when NEMA vs IEC Motor
the operating conditions are well understood. Whereas, NEMA may be chosen when Controls
operating conditions, such as load are not well defined.
Understanding
IP Ratings
IEC contactors are also “finger safe.” Whereas NEMA requires safety covers on
contactor terminals. Another key difference is IEC contactors react faster to overloads,
NEMA contactors are better at withstanding short circuits. 10
IEC vs NEMA Industrial Control

IEC NEMA
Basics:
Part 1, Contactors
Less expensive More expensive
More compact Larger design
Global market North American market Industrial Control
Basics: Part 2,
Less versatile: IEC contactors are specific More versatile: A NEMA contactor can cover Overload Relays
application requirements a broader range of applications
Finger safe Safety covers required
Industrial Control
Faster reaction to overloads Can handle short circuits better
Basics: Part 3,
Starters
People often mistakenly perceive NEMA contactors as more robust. In reality, this is
due to their design being oversized. The Benefits of Type E/F
Motor Protection
Circuit Breakers
The following two tables detail how NEMA and IEC size contactors and starters.
Basic Pump Control:
NEMA Contactor and Starter Sizes Three Phase DOL Starter
Max. Continuous Max. HP Max. HP Max. HP at 480/575
NEMA Size
Amperes at 200 V AC at 230 V AC V AC
00 9 1.5 1.5 2 Applying Motor Control
0 18 3 3 5 in a Wastewater
1 27 7.5 7.5 10 Application
2 45 10 15 25
3 90 25 35 50 NEMA vs IEC Motor
4 135 40 50 100 Controls
5 270 75 100 200
6 540 150 200 400 Understanding
7 810 – 300 600 IP Ratings
8 1215 – 450 900
9 2250 – 800 1600
11
Industrial Control
IEC UTILIZATION CATEGORIES
Basics:
LOW VOLTAGE UTILIZATION CATEGORIES Part 1, Contactors
RELEVANT
NATURE OF IEC PRODUCT
CURRENT CATEGORY TYPICAL APPLICATIONS STANDARD
a.c. AC-1 Non-inductive or slightly inductive loads, resistance furnaces. Industrial Control
AC-2 Slip-ring motors: starting, switching off. Basics: Part 2,
AC-3 Squirrel-cage motors: starting, switching off motors during running. Overload Relays
AC-4 Squirrel-cage motors: starting, plugging1, inching2.
AC-5a Switching of electric discharge lamp control.
AC-5b Switching of incandescent lamps. 60947-4 Industrial Control
AC-6a Switching of transformers. Basics: Part 3,
AC-6b Switching of capacitor banks. Starters
AC-7a Slightly inductive loads in household appliances and similar applications.
AC-7b Motor-loads for household applications.
AC-8a Hermetic refrigerant compressor motor control with manual resetting of overload releases. The Benefits of Type E/F
AC-8b Hermetic refrigerant compressor motor control with automatic resetting of overload releases.
Motor Protection

Circuit Breakers
AC-12 Control of resistive loads and solid-state loads with isolation by optocoupler.
AC-13 Control of solid-state loads with transformer isolation. 60947-5
AC-14 Control of small electromagnetic loads.
AC-15 Control of a.c. electromagnetic loads.
Basic Pump Control:
AC-20 Connecting and disconnecting under no-load conditions. Control of an Electric Pump
AC-21 Switching of resistive loads, including moderate overloads. 60947-3
AC-22 Switching of mixed resistive and inductive loads, including moderate overloads.
AC-23 Switching of motor loads or other highly inductive loads. Applying Motor Control
in a Wastewater
a.c. and A Protection of circuits, with no rated short-time withstand current. 60947-2 Application
d.c. B Protection of circuits, with a rated short-time withstand current.
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
12
Industrial Control
IEC UTILIZATION CATEGORIES (continued)
Basics:
LOW VOLTAGE UTILIZATION CATEGORIES Part 1, Contactors
RELEVANT
NATURE OF IEC PRODUCT
CURRENT CATEGORY TYPICAL APPLICATIONS STANDARD
Industrial Control
d.c. DC-1 Non-inductive or slightly inductive loads, resistance furnaces. Basics: Part 2,
DC-3 Shunt-motors, starting, plugging1, inching2, dynamic breaking of motors. 60947-4 Overload Relays
DC-5 Series-motors, starting, plugging1, inching2, dynamic breaking of motors.
DC-6 Switching of incandescent lamps.
Industrial Control
DC-12 Control of resistive loads and solid-state loads with isolation by optocouplers. Basics: Part 3,
DC-13 Control of d.c. electromagnets. 60947-5 Starters
DC-14 Control of d.c. electromagnetic loads having economy resistors in circuit.
DC-20 Connecting and disconnecting under no-load conditions. The Benefits of Type E/F
DC-21 Switching of resistive loads, including moderate overloads. 60947-3
Motor Protection
DC-22 Switching of mixed resistive and inductive loads, including moderate overloads,
(e.g. shunt motors). Circuit Breakers
DC-23 Switching of highly inductive loads, (e.g. series motors).
By plugging is understood stopping or reversing the motor rapidly by reversing motor primary connections while the motor is running.
1
Basic Pump Control:
By inching (jogging) is understood energizing a motor once or repeatedly for short periods to obtain small movements of the driven mechanis
2

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
13
Figure 3: Double Break Contactors
The example below is a typical IEC Contactor and Thermal Overload Industrial Control
Basics:
Part 1, Contactors
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:

Applications
Lighting Control Applying Motor Control
Contactors are often used to provide central control of large lighting installations, such in a Wastewater
Application
as an office building or retail building. To reduce power consumption in the contactor
coils, latching contactors are used, which have two operating coils. One coil, momenta- NEMA vs IEC Motor
rily energized, closes the power circuit contacts, which are then mechanically held Controls
closed; the second coil opens the contacts.
Understanding
IP Ratings
14
Electric Motor Starter Industrial Control

Basics:
Contactors can be used as a magnetic starter. A magnetic starter is a device designed
Part 1, Contactors
to provide power to electric motors. It includes a contactor as an essential component,
while also providing power-cutoff, under-voltage, and overload protection.
Industrial Control
Basics: Part 2,
Overload Relays
Examples of Motor Control
Industrial Control
Single Phase Electric Motor Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
15
Three Phase Electric Motor Industrial Control

Basics:
Part 1, Contactors
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
16
Star Delta Electric Motor Industrial Control

Basics:
Part 1, Contactors
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:

Summary Applying Motor Control

in a Wastewater
A contactor is a special type of relay used for switching an electrical circuit on or off. Application
They are most commonly used with electric motors and lighting applications. The use of
a contactor provides a level of isolation away from the high electric currents associated NEMA vs IEC Motor
Controls
with those applications, protecting workers and equipment. IEC Contactors are smaller
and are offered in a wide variety of sizes, whereas NEMA contactors are larger and Understanding
designed with safety factors that go beyond design ratings by up to as much as 25%. IEC IP Ratings
is a Global standard. NEMA contactors are primarily used in North America however,
more companies are adopting IEC Contactors, c3controls specializes in IEC.
17
Part 2, Overload Relays Industrial Control
Basics:
Part 1, Contactors
Introduction to Motors Industrial Control

Electric motors are an integral component of industrial equipment, toys, vehicles, and Basics: Part 2,
Overload Relays
electronic devices. They are designed to convert electrical energy into mechanical
energy. These devices may be powered by AC or DC sources. Blowers, fans, Industrial Control
compressors, cranes, extruders, and crushers are a few important devices equipped Basics: Part 3,
Starters
with electric motors.

Motor Protection
What is an Induction Motor? Circuit Breakers
An induction motor, also referred to as a synchronous motor, is one of the main types
of AC electric motors used in commercial and industrial environments. These motors Basic Pump Control:
feature armortisseur windings, and work on the principle of electromagnetic induction. Control of an Electric Pump
The electro-magnetic field in the rotor is produced by the rotating field of the stator. In
short, the power is transferred to the rotor winding by stator through induction. There Applying Motor Control
are two main types of induction motors — single-phase induction motors and three- in a Wastewater
Application
phase induction motors.
NEMA vs IEC Motor
Controls
Introduction to Three-Phase Induction Motors
It is one of the most widely used types of electrical motors; and, is an integral part of Understanding
almost 80% of the industrial applications. Its popularity is due to the rugged construc- IP Ratings
tion, excellent operating characteristics, speed regulation, and absence of commutator.

Like any regular induction motor, this motor also comprises a stator and rotor.
18
Industrial Control Basics: Part 2, Overload Relays
• Stator: This is the stationary element of the induction motor. The stator is a small Industrial Control
Basics:
cylindrical frame which carries the cylindrical core of the rotor. It features Part 1, Contactors
different slotted stampings to carry three-phase windings. The windings of the
stator have 120 degrees separation. Industrial Control
• Rotor: This is the rotating part of the motor. The rotor features laminated Basics: Part 2,
cylindrical slots with copper or aluminum conductors that have joined ends. It is Overload Relays
the shaft of the motor.

Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
The rotor of the three-phase induction motor is classified as phase wound rotor or slip
ring rotor and squirrel cage rotor. Among the two, the squirrel cage rotor is one of the
most common ones.
19
Squirrel Cage Induction Motors Industrial Control

Basics:
Induction motors equipped with a squirrel cage rotor are known as squirrel cage Part 1, Contactors
induction motors. They get their name because the rotor resembles the rotating
cylindrical “cage” that you might find in a pet squirrel or hamster cage. These motors Industrial Control
Basics: Part 2,
are available in sizes ranging from fractional horsepower (HP) less than one kilowatt to
Overload Relays
10,000’s HP (tens of megawatts). Factors such as simplicity, rugged construction, and
constant speed in different load sizes have contributed to their popularity. Like other Industrial Control
induction motors, the squirrel cage motor consists of: Basics: Part 3,
Starters
• Rotor: It is a cylindrical-shaped component mounted on a shaft. It contains The Benefits of Type E/F
Motor Protection
longitudinally organized conductive bars. The bars are made of copper or Circuit Breakers
aluminum, and are set into grooves, which are connected at ends to form a cage-
like structure. The rotor has a laminated core, which helps avoid power loss due Basic Pump Control:
to hysteresis and Eddy currents. Conductors of the rotor are skewed, which Three Phase DOL Starter
helps prevent cogging during the start of the equipment. Also, this skewing assures
improved transformation ratio between the rotor and stator. Applying Motor Control
• Stator: It consists of a three-phase winding along the core. The stator is placed in a Wastewater
Application
in a metal housing. The windings in the stator are organized such that they are
120-degree apart in space, and mounted on a laminated iron core. This iron core
NEMA vs IEC Motor
provides reluctance path for flux generated by AC currents. Controls
Understanding
IP Ratings
20
What is Overload Protection? Industrial Control

Basics:
When the motor draws excess current, it is referred to as an overload. This may Part 1, Contactors
cause overheating of the motor and damage the windings of the motor. Because of
this, it is important to protect the motor, motor branch circuit, and motor branch Industrial Control
Basics: Part 2,
circuit components from overload conditions. Overload relays protect the motor,
Overload Relays
motor branch circuit, and motor branch circuit components from excessive heat from
the overload condition. Overload relays are part of the motor starter (assembly of Industrial Control
contactor plus overload relay). They protect the motor by monitoring the current Basics: Part 3,
Starters
flowing in the circuit. If the current rises above a certain limit over a certain period of
time, then the overload relay will trip, operating an auxiliary contact which interrupts The Benefits of Type E/F
the motor control circuit, de-energizing the contactor. This leads to the removal of the Motor Protection
Circuit Breakers
power to the motor. Without power, the motor and motor circuit components do not
overheat and become damaged. The overload relay can be reset manually, and some
Basic Pump Control:
overload relays will reset automatically after a certain period of time. After which, the Three Phase DOL Starter
motor can be restarted. Control of an Electric Pump

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
21
How an Overload Relay Works Industrial Control

Basics:
The overload relay is wired in series with the motor, so the current that flows to the Part 1, Contactors
motor when the motor is operating also flows through the overload relay. It will trip at
a certain level when there is excess current flowing through it. This causes the circuit Industrial Control
between the motor and the power source to open. The overload relay can be manually Basics: Part 2,
Overload Relays
or automatically reset after a predetermined time duration. The motor can be restarted
after the cause of the overload has been identified and rectified.
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
Types of Overload Relays
1. Bimetallic Overload Relay NEMA vs IEC Motor
Many overload relays include bimetallic elements or bimetallic strips, also referred to Controls
as heater elements. The bi-metallic strips are made of two types of metals – one with
a low coefficient of expansion, and another with a high coefficient of expansion. Understanding
IP Ratings
These bimetallic strips are heated by a winding around the bimetal strip, which
carries the current. Both of the metal strips will expand due to the heat. 22
However, the metal with a high coefficient of expansion will expand more in Industrial Control
Basics:
comparison to the metal with a low coefficient of expansion. This dissimilar expansion Part 1, Contactors
of the bimetallic strips causes the bimetal to bend towards the metal with a low
coefficient of expansion. Industrial Control
Basics: Part 2,
As the strip bends, it actuates an auxiliary contact mechanism and causes the Overload Relays
overload relay normally closed contact to open. As a result, the contactor coil circuit
Industrial Control
is interrupted. Basics: Part 3,
Starters
The amount of heat generated can be calculated by the Joule’s Law of Heating. It is
expressed as H ∝ I2Rt. Motor Protection
Circuit Breakers
• I is the overcurrent flowing through the winding around the bimetal strip of the
overload relay.
Basic Pump Control:
• R is the electrical resistance of the winding around the bimetal strip. Three Phase DOL Starter
• t is the time period for which the current I flows through the winding around the Control of an Electric Pump
bimetal strip.
in a Wastewater
The above equation defines that heat produced by the winding will be directly Application
proportional to the time period of the flow of overcurrent through the winding. In
other words, the lower the current, the longer it will take the overload relay to trip NEMA vs IEC Motor
Controls
and the higher the current, the faster the overload relay will trip, in fact it will trip
much faster because the operation of the relay is a function of the current squared. Understanding
IP Ratings
Bimetallic overload relays are often specified when automatic reset of the circuit is
required, and occurs because the bimetal has cooled and returned to its original state
23
(form). Once this happens the motor can be restarted. If the cause of overload is not Industrial Control
Basics:
rectified, the relay will trip again, and reset at predetermined intervals. It is important Part 1, Contactors
to be careful during the selection of an overload relay, because repeated tripping and
reset can reduce the mechanical life of the relay and may cause damage to the motor. Industrial Control
Basics: Part 2,
In many applications, the motor is installed at a location with a constant ambient Overload Relays
temperature, and the overload relay and motor starter may be installed in a different
Industrial Control
location, which experiences different ambient temperatures. In such applications, the Basics: Part 3,
trip point of the overload relay can vary depending on multiple factors. The current Starters
flow through the motor and the temperature of the surrounding air are two factors,
which may cause premature tripping. In such cases, ambient compensated bimetallic Motor Protection
overload relays are used. The relays of this type feature two types of bi-metal strips Circuit Breakers
– a compensated bi-metal strip and a primary non-compensated bi-metal strip. At
ambient temperatures, both these strips will bend equally, thereby preventing the Basic Pump Control:
overload relay from nuisance tripping. However, the primary bi-metal strip is the Control of an Electric Pump
only strip that gets affected by the current flow through the heater element and the
motor. In the condition of an overload, the trip unit will be engaged by the primary bi- Applying Motor Control
in a Wastewater
metal strip.
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
24
2. Eutectic Overload Relay Industrial Control

Basics:
This type of overload relay is comprised of a heater winding, a mechanical mechanism Part 1, Contactors
for activation of a tripping mechanism, and a eutectic alloy. A eutectic alloy is a
combination of two or more materials, which solidifies or melts at a specific known Industrial Control
temperature. Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
In the the overload relay, the eutectic alloy is contained in a tube, which is often used
along with a spring loaded ratchet wheel to activate the tripping mechanism during NEMA vs IEC Motor
Controls
the overload operations. The motor current passes through the small heater winding.
During the overload, the eutectic alloy tube is heated by the heater winding. The alloy
Understanding
melts due to the heat, thereby releasing the ratchet wheel, and allowing it to turn. IP Ratings
This action initiates the opening of the closed auxiliary contacts in the overload relay.
25
Eutectic overload relays can only be manually reset after tripping. This reset is usually Industrial Control
Basics:
done through a reset button, which is positioned on the cover of the relay. The heater Part 1, Contactors
unit installed on the relay is chosen on the basis of the full load current of the motor.
Industrial Control
3. Solid State Overload Relay Basics: Part 2,
Overload Relays
These relays are commonly referred to as electronic overload relays. Unlike the
bimetallic and eutectic overload relays, these electronic overload relays measure Industrial Control
current electronically. Although available in various designs, they share common Basics: Part 3,
Starters
features and benefits. The heaterless design is one of the main advantages of these
relays. This design helps reduce the costs and efforts of installation. In addition, the
heaterless design is insensitive to the change in ambient temperatures, which helps Motor Protection
minimize nuisance tripping. These relays also provide protection from phase loss – Circuit Breakers
more effectively than bimetallic or eutectic alloy overload relays. These relays can
Basic Pump Control:
easily detect a loss of phase, and operate an auxiliary contact to open the motor Three Phase DOL Starter
control circuit. Solid state overload relays enable easy adjustment of trip times and Control of an Electric Pump
set points.
in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
26
Overload Relay Tripping Industrial Control

Basics:
The tripping time of an overload relay will decrease when the current increases. This Part 1, Contactors
function is plotted on the inverse time curve below, and is termed as the trip class. The
trip class also indicates the time taken by the relay to open in an overload condition. Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
Trip Classes 5, 10, 20, and 30 are common. These classes suggest that the overload NEMA vs IEC Motor
relay will trip in 5, 10, 20, and 30 seconds. This tripping usually occurs when the motor Controls
is running 720% of its full load. Trip Class 5 is suited for motors that demand fast
Understanding
tripping, whereas Class 10 is usually preferred for motors of low thermal capacity like IP Ratings
submersible pumps. Class 10 and 20 are employed for general purpose applications,
whereas Class 30 is employed for loads with high inertia. Class 30 relays help avoid
nuisance tripping. 27
Summary Industrial Control

Basics:
When a motor draws excess current, it is referred to as an overload, causing possible Part 1, Contactors
overheating and damage to the windings of the motor. Overload relays protect the
motor, motor branch circuit, and motor branch circuit components from possible Industrial Control
Basics: Part 2,
damage. Being part of the motor starter assembly, overload relays protect the motor
Overload Relays
by monitoring the current flowing in the circuit. Three types of overload relays are:
Bimetallic, Eutectic, and Solid State. Each type of overload has its own unique way Industrial Control
of sensing overcurrent. The best type of relay to use is based on the application and Basics: Part 3,
Starters
discretion of the installation team.
Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
28
Part 3 - Starters
Industrial Control
Basics:
Part 1, Contactors
Introduction Industrial Control

Basics: Part 2,
Motor starters are one of the major inventions for motor control applications. As the
Overload Relays
name suggests, a starter is an electrical device which controls the electrical power for
starting a motor. These electrical devices are also used for the purpose of stopping,
Industrial Control
reversing and protecting electric motors. The following are the two major components Basics: Part 3,
of a starter: Starters

1. Contactor: The main function of the contactor is to control the electric current to Motor Protection
the motor. A contactor can make or break power to the circuit. Circuit Breakers
2. Overload Relay: Overheating and drawing too much current can cause the motor
to burn out and become practically useless. Overload relays prevent this from Basic Pump Control:
happening and protect the motor from any potential danger. Control of an Electric Pump

A starter is an assembly of these two components, which allows it to turn on or off an
in a Wastewater
electric motor or motor controlled electrical equipment. The starter also provides the Application
necessary overload protection to the circuit.
NEMA vs IEC Motor
Controls
Understanding
IP Ratings
29
Industrial Control Basics: Part 3, Starters
Industrial Control
Types of Motor Starters Basics:
There are several types of motor starters. However, the two most basic types of these Part 1, Contactors
electrical devices are:
Industrial Control
Basics: Part 2,
1. Manual Starters Overload Relays
Manual starters are devices that are operated manually. These starters are extremely
easy and straightforward to operate and do not require expert intervention. The Industrial Control
starter includes a button (or rotary knob) which enables a user to turn the connected Basics: Part 3,
Starters
equipment on or off. The buttons features mechanical linkages, which make the
contacts open or close, starting or stopping the motor. The following features of a The Benefits of Type E/F
manual starter make it a preferred choice over other types: Motor Protection
Circuit Breakers
• These starters deliver a safe, as well as economical operation. Basic Pump Control:
• The compact size of these devices make them suitable for a wide range of Three Phase DOL Starter
applications.
• They provide overload protection to the motor, protecting it from any potential
damage. in a Wastewater
Application
• These devices come with a vast choice of enclosures.
• The initial cost of the manual starter is low.
NEMA vs IEC Motor
Controls
Understanding
IP Ratings
30
2. Magnetic Motor Starters Industrial Control

Basics:
This is the other main type of motor starter. It is operated electromagnetically. It Part 1, Contactors
means that the motor load connected to the motor starter is typically started and
stopped using a lower and safer voltage than the motor voltage. Just like other motor Industrial Control
Basics: Part 2,
starters, the magnetic starter also has an electrical contactor and overload relay to
Overload Relays
protect the device from too much current or overheating.
Industrial Control
Magnetic Motor Starter Circuitry & Operation Basics: Part 3,
Starters
Motor Starter Power Circuity
Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
31
There are two circuits in a motor starter, which are as follows: Industrial Control
Basics:
Part 1, Contactors
1. Power Circuit: The power circuit connects the line to the motor. It provides
transmission of electricity through the starter contacts, overload relay, and then Industrial Control
Basics: Part 2,
to the motor. The motor current is carried by the power (main) contacts of the Overload Relays
contactor.
2. Control Circuit: This is the other motor starter circuit, which operates the Industrial Control
contactor to turn it on or off. The contactors main contacts are responsible for Basics: Part 3,
Starters
allowing or interrupting the flow of current to the motor. To do this, the contacts
in the control circuit are either opened or closed. The control circuit energizes the
contactor coil, which creates an electromagnetic field. The power contacts are Motor Protection
pulled by this electromagnetic field to a closed position. This completes the circuit Circuit Breakers
between the motor and the line. This way, remote operations are made possible by
Basic Pump Control:
the control circuit. The control circuit can be wired in the following two ways: Three Phase DOL Starter
Method 1: One of the most widely used methods employed for wiring the control
circuit is referred to as the “Two-wire method”. A maintained contact type of pilot
in a Wastewater
device like presence sensor, thermostat, or float switch is used in the two-wire Application
method of wiring the control circuit.
Method 2: Unlike the two-wire method, the “Three-wire method” of wiring the NEMA vs IEC Motor
Controls
control circuit uses a holding circuit contact and the momentary contact pilot
devices.
Understanding
IP Ratings
32
The control circuit can derive the power from either of the following three ways: Industrial Control
Basics:
Part 1, Contactors
• Common Control: This type of control is when the power source of the control
circuit is the same as the motor. Industrial Control
Basics: Part 2,
• Separate Control: This is the most popular type of control. As the name Overload Relays
suggests, the control circuit derives power from a separate source in this
arrangement. Generally, the power derived is lower in voltage as compared to Industrial Control
the motor’s power source. Basics: Part 3,
• Transformer Control: As the name suggests, the control circuit derives power Starters
from a control circuit transformer. Generally, the power derived is lower in

voltage as compared to the motor’s power source. Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
33
Industrial Control
Types of Magnetic Motor Starters Basics:
Depending on how they are connected in a circuit, there are many types of magnetic Part 1, Contactors
motor starters, such as:

Industrial Control
Basics: Part 2,
1. Direct-On-Line Starter Overload Relays
Direct-On-Line Starter Industrial Control

Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
34
The direct-on-line starter is the simplest form of motor starter, other than a manual Industrial Control
Basics:
starter. The controller of this starter is typically a simple push button (but could be a Part 1, Contactors
selector switch, limit switch, float switch, etc.). Pressing the start button closes the
contactor (by energizing the contactor coil) connected to the main supply and motor. Industrial Control
Basics: Part 2,
This provides the supply current to the motor. To turn the motor off, a stop button Overload Relays
is provided. To protect it from over current, the control circuit is wired through a
normally closed auxiliary contact of the overload relay. When the overload relay trips, Industrial Control
the normally closed auxiliary contact opens, and de-energizes the contactor coil, and Basics: Part 3,
the contactor main contacts open. Starters

The Advantages of Using Direct-On-Line Motor Starters: Motor Protection
• They have a compact design. Circuit Breakers
• They are cost-effective.

Basic Pump Control:
• They have a simple construction. Three Phase DOL Starter

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
35
2. Rotor Resistance Starter Industrial Control

Basics:
Part 1, Contactors
Rotor Resistance Starter
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
In the rotor resistance starter, the three resistances are connected such that they are
in series with the rotor windings. This helps reduce the rotor current considerably, as Basic Pump Control:
well as increases the motor torque. Control of an Electric Pump
The Advantages of Using Rotor Resistance Motor Starters: Applying Motor Control
in a Wastewater
• They are cost-effective. Application
• They have a simple speed control method.
• They provide low starting current, large starting torque, and large pull-out NEMA vs IEC Motor
Controls
torque.
Understanding
IP Ratings
36
3. Stator Resistance Starter Industrial Control

Basics:
Part 1, Contactors
Stator Resistance Starter
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:

The stator resistance starter consists of three resistors, which are connected in series Control of an Electric Pump
with each phase of the stator windings. At each resistor, a voltage drop is caused, so
it becomes necessary to apply low voltage to each phase. These resistances are set in a Wastewater
at the start or maximum position during the motor start stage. The starting current is Application
kept at a minimum in this type of starter. Also, the starting torque to the motor needs
to be maintained. NEMA vs IEC Motor
Controls
The Advantages of Using Stator Resistance Motor Starters: Understanding

• They are suitable for use in speed control applications. IP Ratings
• They have extremely flexible starting characteristics.

• They provide smooth acceleration.
37
4. Auto Transformer Starter Industrial Control

Basics:
Part 1, Contactors
Auto Transformer Starter
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:

With an auto transformer starter, the transformer supplies a certain percentage Applying Motor Control
of the primary voltage to the secondary of the transformer. The auto transformer in a Wastewater
Application
is connected in a star configuration. The three tapped secondary coils of the
transformer are connected to the three motor phases in this type of starter. This
NEMA vs IEC Motor
helps in reducing the voltage that is being applied to the motor terminals. Controls
Understanding
The Advantages of Using Auto Transformer Motor Starters:
IP Ratings
• They can be used for manual speed control, but with limited options.
• They have extremely flexible starting characteristics.
• They have a high output torque. 38
5. Star Delta Starter Industrial Control

Basics:
Part 1, Contactors
Star Delta Starter
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:

Compared to the other types of starters, the star delta starter is used on a large scale.
As the name suggests, the three windings are connected in a star connection in the Applying Motor Control
star delta starters. A certain time is set by the timer or any other controller circuit. in a Wastewater
Application
After this time is passed, the windings are then connected in the delta connection.
The phase voltage in the star connection is reduced to 58%, and the total current
NEMA vs IEC Motor
drawn is 58% of normal current. This results in a reduced torque. Controls
The Advantages of Using Star Delta Motor Starters: Understanding

IP Ratings
• They are ideal for long acceleration times.
• They have a lower input surge current when compared to other starters.
• They have a simpler construction as compared to other starters.
39
Industrial Control
Features of Motor Starters Basics:
Today, motor starters are used on a large scale due to their list of beneficial features. Part 1, Contactors
The following are some features of these highly useful electrical devices:
Industrial Control
Basics: Part 2,
• They facilitate the starting and stopping of the motor. Overload Relays
• The starters are rated by power (horsepower, kilowatt) and current (amperes).
• They provide the necessary overload protection for the motor. Industrial Control
Basics: Part 3,
• The electrical device facilitates remote on/off control feature.
Starters
• These devices allow you to make and break current rapidly (plugging and jogging).
Motor Protection
Fundamental Functions of Motor Starters Circuit Breakers
The following are the most fundamental functions that a starter has to perform:
Basic Pump Control:
1. Control: The control function is mainly carried out by the contactor component of Control of an Electric Pump
a starter. It is controlling the opening and closing of the power electrical circuit. The
switching is done by the main contacts (poles) of the contactor. An electromagnetic Applying Motor Control
in a Wastewater
coil is energized, which open or close the contacts. This electromagnetic coil has a Application
nominal control voltage, and can either be an AC or DC voltage.
2. Short-Circuit Protection: In industrial applications, normal load current can be NEMA vs IEC Motor
up to thousands of amperes. In the case of a short-circuit fault, the fault current Controls
can go over 100,000 amperes. This can cause severe damage to the equipment. The
Understanding
short-circuit protection disconnects the supply and prevents the potential damage IP Ratings
in a safe manner. Short circuit protection is provided by fuses or circuit breakers in a
Combination Motor Controller.
40
3. Overload Protection: When a motor draws more current than it is designed to, an Industrial Control
Basics:
overload condition is caused. The main objective of an overload relay is to detect the Part 1, Contactors
excess currents. When an overload is detected, the auxiliary contact of the overload
relay opens the circuit and prevents the motor from burning out or overheating. Industrial Control
Basics: Part 2,
Electronic or electromechanical overload relays are used in combination with a Overload Relays
contactor to provide the required overload protection.
Industrial Control
4. Disconnecting and Breaking: In order to prevent an unintended restart, it is Basics: Part 3,
required to disconnect the motor from the main power circuit. In order to safely Starters
perform maintenance on a motor or starter, a motor must be able to switch off and be
isolated from the power. The disconnect switch of the circuit provides this function. The Benefits of Type E/F
Motor Protection
Disconnecting and breaking is provided by a disconnect switch or circuit breaker in a Circuit Breakers
Combination Motor Controller (or can be installed remotely from the starter).
Basic Pump Control:

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
41
Standards and Ratings Industrial Control

Basics:
There are many factors involved in motor starter ratings, such as thermal current, Part 1, Contactors
continuous current, motor voltage, and power.

Industrial Control
Basics: Part 2,
The thermal current is dependent on the thermal conductivity (k), which is the property Overload Relays
indicating the heat conducting ability of a material. It means that thermal current is
directly proportional to the thermal conductivity. Industrial Control
Basics: Part 3,
Starters
The continuous current, which is also commonly referred to as the continuous ampere
rating is a measure of the capability of the motor control starter to handle current for a
continuous time. Motor Protection
Circuit Breakers
The power rating of the motor starter is based on the type of motor used. DC motor
Basic Pump Control:
starters have ratings for DC horsepower. On the other hand, AC motor starters have a Three Phase DOL Starter
single-phase power and three-phase power rating. Control of an Electric Pump
The rating of the motor starter is based on the size and type of load for which it Applying Motor Control
in a Wastewater
was designed. Starters conform to the standards and ratings from Underwriters Application
Laboratories (UL), Canadian Standards Association (CSA), International
Electrotechnical Commission (IEC) and National Electrical Manufacturers Association NEMA vs IEC Motor
Controls
(NEMA).
Understanding
IP Ratings
42
NEMA Rating Industrial Control

Basics:
The NEMA ratings of a starter depends largely on the maximum horsepower ratings Part 1, Contactors
given in the National Electrical Manufacturers Association ISCS2 standard. The
selection of the NEMA starters is done on the basis of their NEMA size, which varies Industrial Control
Basics: Part 2,
from Size 00 to Size 9.
Overload Relays
NEMA Contactor and Starter Sizes

NEMA Size Continuous AMP Rating HP at 230 VAC HP at 460 VAC
Industrial Control
Basics: Part 3,
00 9 1 2
Starters
0 18 3 5
1 27 5 10
2 45 15 25 The Benefits of Type E/F
3 90 30 50
Motor Protection
Circuit Breakers
4 135 50 100
5 270 100 200
6 540 200 400 Basic Pump Control:
7
810 300 600
8 1215 450 900
9 2250 800 1600
in a Wastewater
The NEMA starter, at its stated rating, can be used for a wide range of applications, Application
ranging from simple on and off applications to plugging and jogging applications,
which are more demanding. It is necessary to know the voltage and horsepower of NEMA vs IEC Motor
Controls
the motor when selecting the proper NEMA motor starter. In the case where there is
a considerable amount of plugging and jogging involved, then derating a NEMA-rated
Understanding
device will be required. IP Ratings
43
IEC Rating Industrial Control

Basics:
The International Electrotechnical Commission (IEC) has specified the operational Part 1, Contactors
and performance characteristics for IEC devices in the publication IEC 60947.
Standard sizes are not specified by the IEC. The typical duty cycle of IEC devices are Industrial Control
Basics: Part 2,
defined by utilization categories. As far as general motor starting applications are Overload Relays
concerned, the AC3 and AC4 are the most common utilization categories.
Industrial Control
IEC Rating
Basics: Part 3,
Utilization Category IEC Category Description
Starters
AC1 Non-inductive or slightly induction rows
AC2 Starting of slip-ring motors
AC3 Starting of squirrel-cage motors and switching off only when the motor is up to speed.
Motor Protection
(Make LRA, Break FLA)
Circuit Breakers
AC4 Starting of squirrel-cage motors with inching and plugging duty. Rapid Start/Stop. (Make
and Break LRA)
AC11 Auxiliary (control) circuits Basic Pump Control:
Unlike NEMA sizes, they are typically rated by their maximum operating current,
thermal current, HP and/or kW rating. Applying Motor Control
in a Wastewater
Application
There are other parameters that are important to consider when selecting motor
starters, such as time-limit acceleration, current-line acceleration, control voltage, NEMA vs IEC Motor
number of poles, and operating temperature. These parameters are not covered in Controls
this article.
Understanding
IP Ratings
44

Basics:
A starter is an electrical device which controls the power for starting a motor. These Part 1, Contactors
electrical devices are also used for the purpose of controlling the motor, short circuit
Industrial Control
and overload protection, and disconnecting and breaking and are made of two major Basics: Part 2,
components: a contactor and overload relay. While there are many types of starters, Overload Relays
the two most basic starters are manual and magnetic. Thermal current, continuous
current, motor voltage, and power are just a few factors of the starter’s rating, as well Industrial Control
as its size and type of load. NEMA starters are sized based on horsepower and primarily Basics: Part 3,
Starters
used in North America. IEC starters are used world wide and sized by their maximum
operating current.
Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
45
The Benefits of Type E/Type F
Motor Protection Circuit Breakers
Industrial Control
Basics:
Part 1, Contactors
Motor Control Configuration Challenges Industrial Control

Basics: Part 2,
Designing motor-driven electrical equipment and panels can be a labor-intensive Overload Relays
process due to installation requirements mandated by NFPA 70 National Electric
Code (NEC) Article 430: Motors, Motor Circuits, and Controllers, which defines the Industrial Control
Basics: Part 3,
requirements for all motor branch circuits and the operational functionality of panel Starters
devices to include:
• Motor disconnecting means – disconnect switch, molded case switch or molded Motor Protection
case circuit breakers Circuit Breakers
• Motor branch-circuit, short-circuit, and ground fault protection – molded case
Basic Pump Control:
circuit breaker or fuses Three Phase DOL Starter
• Motor controller – contactor Control of an Electric Pump
• Motor overload protection – thermal overload relay

in a Wastewater
Electrical control products must be able to be used globally in addition to being Application
compliant with NEC codes and standards. To ensure compliance with NEC codes, third
NEMA vs IEC Motor
party certifications (such as Underwriters Laboratories) and international standards, Controls
controls engineers often times would size and install individual single function devices
that would meet all industry specifications. Understanding
IP Ratings
These efforts resulted in panels being packed with multiple controls with each
individual device requiring proper sizing and spacing to fit within the panel — resulting
46
The Benefits of Type E/F Motor Protection Circuit Breakershe
in larger enclosures, increased panel complexity, decreased configuration flexibility, and Industrial Control
Basics:
a higher overall installation cost. Part 1, Contactors
There had to be a better way — Simplify the motor disconnect, control, and protection Industrial Control
processes by reducing the number of panel components by creating a multi-functional, Basics: Part 2,
Overload Relays
standalone replacement component.
Industrial Control
The expansion of the IEC motor protection circuit breaker’s performance could provide Basics: Part 3,
Starters
all of the motor protection functions required by NEC Article 430:
Supply The Benefits of Type E/F

Part II
Motor Protection
Motor feeder 430.24, Circuit Breakers
430.25, 430.26
Motor feeder
short-circuit and Part V Basic Pump Control:
ground-fault protection
Motor disconnecting
Part IX Control of an Electric Pump
means
Motor branch-circuit,
short circuit, and Part IV
ground-fault protection Applying Motor Control
in a Wastewater
Motor circuit conductor Part II
Application
Motor controller Part VII
Motor control circuits Part VI
Motor overload protection Part III NEMA vs IEC Motor

Motor Part I
Controls
Thermal protection Part III

Understanding
Secondary controller Part II
Secondary conductors 430.23 IP Ratings
Part II
Secondary resistor 430.23 and
Article 470
47
At c3controls, this approach resulted in a UL Listed Type E/Type F combination motor Industrial Control
Basics:
controller, which provides motor disconnecting means, branch-circuit, short-circuit, Part 1, Contactors
and ground fault protection as well as motor control and overload protection.
Industrial Control
Basics: Part 2,
These multi-functional devices come installed with: Overload Relays
• Series 330 thermal and magnetic motor protection circuit breaker (c3controls’ Industrial Control
Basics: Part 3,
catalog number 330-T25)
Starters
• Line side terminal barrier (c3controls’ catalog number 330-LSTB25)
• Trip indicating auxiliary contact module (c3controls’ catalog number The Benefits of Type E/F
330-STA22S25) Motor Protection
Circuit Breakers
Line Side
Terminal Barrier Basic Pump Control:

in a Wastewater
Application
Trip Indicating
NEMA vs IEC Motor
Auxiliary Contact Controls
Understanding
IP Ratings
48
The Type E manual, self-protected combination motor controller was tested with Industrial Control
Basics:
a Series 300 Contactor creating a Series 630 Direct-On-Line Starter, providing the Part 1, Contactors
customer with the option to take advantage of the contactor’s extended switching life,
while simultaneously achieving the required motor disconnect capability and short Industrial Control
Basics: Part 2,
circuit/overload protection. Overload Relays
Type F construction is very similar to Type E with the following exceptions: Industrial Control
Basics: Part 3,
Starters
Type E vs. Type F
Type E Type F
The entire assembly is self-protected. Same combination kA ratings as Type E.
Motor Protection
There is a separate set of short circuit and endurance
performance tests just for Type E self-protected
Only the manual motor starter is Circuit Breakers
self-protected.
category.
The entire assembly is subjected to the Type E short The contactor is not subjected to the Type E short circuit Basic Pump Control:
circuit and endurance performance tests. and endurance performance tests. Three Phase DOL Starter
Since the contactor is not part of the self-protected test, the Type F combination motor
controller will clear a short and protect equipment and operators, but the device may
in a Wastewater
not be operational immediately after a fault occurs. Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
49
Industrial Control
Type E/Type F Benefits Basics:
A Type E self-protected combination motor controller can be specified as either a Part 1, Contactors
Series 330 or a Series 630, while a Type F self-protected combination motor controller
Industrial Control
is specified as a Series 630. As a result, c3controls’ customers can take advantage of Basics: Part 2,
our single part number cataloging system to order a complete starter assembly. If more Overload Relays
configuration flexibility is required, he or she can take advantage of the modularity of
the device and purchase the desired components separately. Industrial Control
Basics: Part 3,
Starters
c3controls’ Type E/Type F combination motor controllers are optimized for single
motor or few motor (less than 3) applications and provide the greatest benefit when The Benefits of Type E/F
used with any three phase motor ≤20Hp @ 460VAC that requires Trip Class 10 thermal Motor Protection
overload protection. Both Series 330 and Series 630 devices mount onto a single 35mm Circuit Breakers
DIN Rail or can be panel mounted, reducing labor costs and making installation quick
Basic Pump Control:
and easy. Three Phase DOL Starter

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
50
Application Summary Industrial Control

Basics:
Single Motor
Part 1, Contactors
Multi-Motor Group Type E Construction
Installation Installation Installation Installation
Industrial Control
Basics: Part 2,
Disconnect
Overload Relays
Set of Fuses Industrial Control

or Circuit
Breaker Basics: Part 3,
(S.P.C.D) Starters
Contactor The Benefits of Type E/F

(Controller)
Motor Protection
Overload
Relay
Circuit Breakers
Motor
Basic Pump Control:
c3controls’ users do not need to identify and size additional short circuit protective
devices. Rather, these are determined by the self-protected combination motor Applying Motor Control
in a Wastewater
controller. As a result, customers who purchase Type E/Type F devices will recognize Application
simpler bills of materials, reduced inventory requirements, and lower overall costs.
NEMA vs IEC Motor
Controls
The lock-off features of these devices ensure safety during maintenance and repair.
The trip indicator allows a user to determine which type of fault has occurred, whether
Understanding
overload or short circuit, to ensure timely resolutions and minimal operational IP Ratings
downtime. Additionally, since the Type E device is self-protected, equipment does not
need to be replaced once a fault occurrence has been resolved.
51
The Type E/Type F combination motor controller’s compact design and multi- Industrial Control
Basics:
functionality reduce panel space requirements allowing customers to increase panel Part 1, Contactors
density using smaller enclosures, which result in lower installation costs. Furthermore,
the decreased number of total panel components and increased ease of specification Industrial Control
Basics: Part 2,
produce panels and machines capable of operating with more function at lower overall
Overload Relays
costs.
Industrial Control
c3controls’ Type E/Type F combination motor controllers provide the kind of high Basics: Part 3,
Starters
functionality, simplistic specification and ease of installation that our customers require
at a value unmatched in the electrical controls industry. These product features and
benefits combined with c3controls’ factory direct pricing, lifetime warranty, and
Motor Protection
guaranteed same day shipping make Type E/Type F combination motor controllers your Circuit Breakers
one-stop motor control solution.
Basic Pump Control:
For more information about c3controls’ IEC motor control product line, visit us at Control of an Electric Pump
www.c3controls.com/products/direct-on-line-starters
in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
52
Basic Pump Control: Three Phase DOL Starter Control of an Electric Pump
Industrial Control
Basics:
Part 1, Contactors
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


Basic Pump Control: Three Phase DOL Starter Control of an in a Wastewater
Electric Pump Application
Watch this video to learn how to wire a three-phase DOL (Direct-On-Line) starter to
NEMA vs IEC Motor
a pump motor. The video demonstrates the three types of wiring: Power, Control, and Controls
Indication wiring, using a 3-pole circuit breaker, starter (contactor and overload assembly),
pushbuttons, pilot lights, e-stop, and selector switch. Understanding
IP Ratings
53
Applying Motor Control in a
Wastewater Application Industrial Control
Basics:
Part 1, Contactors
This article will cover the basic building blocks of pump control. It is not intended to be the Industrial Control
end-all for water and wastewater applications, but rather an introduction. Basics: Part 2,
Overload Relays
Introduction Industrial Control

Basics: Part 3,
Water and waste water treatment requires moving water through the different stages Starters
of treatment. To do that, pump stations are used. Each part or station of the water
treatment process can require a different type of pump. While the pumps are different, The Benefits of Type E/F
they all share the common architecture of an electric motor and a method of controlling Motor Protection
Circuit Breakers
those motors.
Basic Pump Control:
According to the US EPA, pump station capacities range from 76 lpm (20 gpm) to Three Phase DOL Starter
more than 378,500 lpm (100,000 gpm). Prefabricated pump stations generally have a
capacity of up to 38,000 lpm (10,000 gpm). Usually, pump stations include at least two
constant-speed pumps ranging in size from 38 to 75,660 lpm (10 to 20,000 gpm) each in a Wastewater
and have a basic wet-well level control system to sequence the pumps during normal Application
operation. Source: EPA 832-F-00-069, September 2000
NEMA vs IEC Motor
Controls
The process of moving water is extremely energy-intensive. In the US, electric motor-
driven devices, including pumps, use almost 65%-70% of all electricity produced in the
Understanding
country. Water and wastewater systems are known to utilize almost 50% of the energy IP Ratings
in any municipality, of which 90% of the energy is used by pumps.
54
Applying Motor Control in a Wastewater Application
Liquid level switches and sensors trigger when a desirable water level is attained. Industrial Control
Basics:
Trapped air column, or bubbler system that senses pressure and level, are commonly Part 1, Contactors
used for pump station controls. Other control alternatives are electrodes placed at cut-
off levels and float switches. These sensors and switches signal the pump motor control Industrial Control
systems to keep the water treatment process flowing and achieving optimum process Basics: Part 2,
Overload Relays
efficiencies.
Industrial Control
Municipal water systems use pumps to draw raw water from resources, such as lakes Basics: Part 3,
Starters
or rivers, for treatment to meet regulatory standards for potable water for human
consumption or use in cooling towers, boilers, and other industrial applications.
Motor Protection
Circuit Breakers
Types of Pumps used in the Water and Wastewater Industry
Water and wastewater management has become a priority in industries such as Basic Pump Control:
chemical manufacturing, energy production, and food and pharmaceutical processing. Three Phase DOL Starter
The quality of water treatment entirely depends on the type of process employed.
These treatment plants employ primary, secondary, and tertiary processes that vary
depending on the level of contaminants in the water. The following are some popular in a Wastewater
pumps largely used in water and wastewater industry for water treatment. Application
NEMA vs IEC Motor

• Positive Displacement Pumps • Airlift Pumps Controls
• Centrifugal Pumps • Trash Pumps
• Submersible Pumps • Water Pressure Booster Pumps Understanding
• Rotary Lobe Pumps • Agitator Pumps IP Ratings
• Peristaltic Pumps • Circulation Pumps

• Progressive Cavity Pumps
55
Examples of Positive Displacement Pumps Industrial Control

Basics:
Part 1, Contactors
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
56
Examples of where different types of pumps can be used are shown in the table below. Industrial Control
Basics:
Part 1, Contactors
Pump Application
Pump Type Typical Application
Industrial Control
Centrifugal Raw Wastewater Flush Water
Basics: Part 2,
Primary Sludge Spray Water Overload Relays
Secondary Sludge Seal Water
Effluent Wastewater
Industrial Control
Positive Displacement Primary Sludge
Basics: Part 3,
Thickened Sludge Starters
Digested Sludge
Slurries
Chemical Feed Applications
Motor Protection
Progressive Cavity All types of Sludge Circuit Breakers
All types of Slurries
Source: WEF, 1992 and Sanks, 1992
Basic Pump Control:

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
57
Proper pump, motor, and controls selection optimizes the performance of water Industrial Control
Basics:
treatment systems and can provide energy savings of 20% - 50%. Selecting a pump with Part 1, Contactors
the correct characteristics is achieved by studying pump performance curves. Below is
an example of an ESP (Electric Submersible Pump) pump performance curve. Industrial Control
Basics: Part 2,
Overload Relays
Example: ESP (Electric Submersible Pump) Pump Performanc Curve
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Source: Typical ESP pump performance curves (figure courtesy of Wood Group ESP, Inc., Oklahoma City, OK, USA) Understanding
IP Ratings
Horsepower motor load is the determining factor when selecting the correct motor
controls.
58
Types of Motor Controls used with Water and Wastewater Pumps Industrial Control
Basics:
1. Contactor: Part 1, Contactors
Contactors are components designed to switch on and off heavy loads in pump
Industrial Control
motors. These components feature main contacts (poles), auxiliary contacts, Basics: Part 2,
and an operating coil. They energize the contactor to switch on and off the main Overload Relays
contacts. Auxiliary contacts are designed for controlling and signaling various
circuit applications, whereas main contacts are the current carrying parts of these Industrial Control
Basics: Part 3,
contactors. Starters
Typically these contactors feature 3-pole electrically operated switches, which take The Benefits of Type E/F
less space when installed inside electrical enclosures. The motors used in water Motor Protection
Circuit Breakers
treatment and wastewater treatment pumps are known to draw more energy at any
voltage. The possibility of electric shock increases at high voltage and may cause Basic Pump Control:
heavy damage. However, AC and DC contactors are safe to use while starting the Three Phase DOL Starter
motor, as there is no current flow between the circuit powering a contactor and the
circuit being switched.
in a Wastewater
The contactors are mounted so they do not touch the circuit that is being switched. Application
Because these contactors use less power than the main switching circuit, they help
reduce power consumption. Advanced motor contactors feature compact designs, NEMA vs IEC Motor
Controls
which further help reduce the footprint of the device and its power consumption.
Understanding
IP Ratings
59
2. Overload Relay: Industrial Control

Basics:
When a motor draws excess current, it is referred to as an overload. This may cause Part 1, Contactors
overheating of the motor and damage the windings of the motor. Because of this,
it is important to protect the motor, motor branch circuit, and motor branch circuit Industrial Control
components from overload conditions. Overload or overheating is one of the major Basics: Part 2,
Overload Relays
reasons for pump failure. Overload Relays protect the pump’s motor from these
conditions.
Industrial Control
Basics: Part 3,
Starters
Designed as electromechanical devices, overload relays are distinguished as
bimetallic, melting alloy, or solid-state electronic relays on the basis of their
construction. Motor Protection
Circuit Breakers
Bimetallic overload relays are one of the most common types of overload protection
Basic Pump Control:
devices, and they feature adjustable trip points. Bimetallic overloads are engineered Three Phase DOL Starter
for automatic reclosing and compensate to prevent ambient temperature changes. Control of an Electric Pump
In addition, these overload relays protect motors in extreme temperature
environments. Applying Motor Control
in a Wastewater
Application
Advanced bimetallic overload relays feature manual or automatic reset and test
modes and a stop button that enables better device management. Many of these NEMA vs IEC Motor
relays possess single phase sensitivity, which helps protect motors against phase loss Controls
conditions. These relays are provided in three trip class ratings:
Understanding
IP Ratings
60
• Class 10 is a quick trip rating, suitable for submersible pumps used in water and Industrial Control
Basics:
wastewater industries. This rating indicates that the bimetallic overload relay Part 1, Contactors
will trip automatically within 10 seconds of the overload condition.
• Class 20 is the standard and ideal for general motor applications. Industrial Control
• Class 30 is a slow trip rating, which is suited for motors that drive high inertia Basics: Part 2,
Overload Relays
loads and require long starting periods.
Industrial Control
These features help minimize energy consumption and increase motor efficiency. Basics: Part 3,
Starters
3. Motor Protection Circuit Breaker: The Benefits of Type E/F

Designed for protecting motors from short circuits, phase-loss, and overloads, motor Motor Protection
Circuit Breakers
protection circuit breakers (MPCB’s) are alternatives to thermal overload relays, and
are equipped with several advanced features. Basic Pump Control:
Commonly used in many water pumping systems, these circuit protection
components are used as manual motor controllers or paired with contactors in
several multi-motor applications. Motor protection circuit breakers are mainly in a Wastewater
distinguished as open or enclosed. The difference between these types is where Application
the circuit breaker is secured, either inside an enclosure or open in the panel. Most
advanced motor protection circuit breakers offer space savings, as they are designed NEMA vs IEC Motor
Controls
without individual motor branch circuit fuses, overload relays, or circuit breakers.
Understanding
IP Ratings
61
4. Direct-On-Line (DOL) Motor Starter: Industrial Control

Basics:
As the name suggests, these devices are used to start electric motors of pumps Part 1, Contactors
and other electronic devices such as compressors, conveyor belts, and fans. A
motor starter features various electronic and electro-mechanical devices such as Industrial Control
a contactor paired with a motor protection circuit breaker or an overload relay. Basics: Part 2,
Overload Relays
DOL starters are used to start small water pumps because they provide several
advantages such as 100% torque during starting, simplified control circuitry, easy
Industrial Control
installation and maintenance, and minimal wiring. Enclosed DOL Motor Starters are Basics: Part 3,
also an option, where the entire starter assembly is placed inside an enclosure. Starters

5. Programmable Logic Controller (PLC): Motor Protection
The programmable logic controller or PLC is really an industrialized computer that Circuit Breakers
operates without a keyboard or monitor. Originally, the PLC was a replacement for
Basic Pump Control:
large panels of relays that switched on and off, controlling a machine operation. The
programming language of the PLC mimicked the Relay Logic, making the transition Control of an Electric Pump
from relays to PLC’s an easy to understand process. Today’s PLC’s offer much more
complex operational capabilities and communications via Ethernet or proprietary Applying Motor Control
networks. The ability to control multiple pumps in a coordinated fashion makes PLC’s in a Wastewater
Application
a common component of water management systems.
NEMA vs IEC Motor
6. Variable Frequency Drive (VFD): Controls
They’re used for running an AC motor at variable speeds or to ramp up speed for
smoother start up. VFD’s control the frequency of the motor to adjust the pump Understanding
IP Ratings
motor RPM’s. VFD’s are widely used to regulate water flow at a water treatment
plant, allowing more control over the flow of the pump.
62
7. Soft Starter: Industrial Control

Basics:
Between the simplicity of a DOL motor starter and the complexity of a VFD sits the Part 1, Contactors
Soft Starter. Electric motors often require large amounts of electricity during their
acceleration. A soft starter can be used to limit the surge of current torque of the Industrial Control
electric motors, resulting in a smoother startup. Soft starters can protect an electric Basics: Part 2,
Overload Relays
motor from possible damage and at the same time extend the lifespan of your electric
motor by reducing the heat caused by frequent starting and stopping. Soft Starters
Industrial Control
limit the large inrush current demands on the electrical supply system. Soft Starters Basics: Part 3,
Starters
are used with pumps in a process which requires to bring them up slowly to reduce
pressure surges in the water system.
Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
63
Tips when Selecting Motor Controls for use with Water and Industrial Control
Basics:
Wastewater Pumps Part 1, Contactors
Contactors Industrial Control

Basics: Part 2,
These devices are often confused with relays, however, the main difference is Overload Relays
contactors can easily switch higher currents and voltages, whereas the relay is used for
lower current applications. Keep the following in mind when selecting contactors for Industrial Control
your motors: Basics: Part 3,
Starters
• Decide what amount of current, FLA - Full Load Amperage will be required to power
your pump motor. The Benefits of Type E/F
Motor Protection
• Select the coil voltage for AC or DC operation based on your motor horsepower, Circuit Breakers
input voltage, and single or 3-phase. Coils are mainly offered in control voltages
such as 24VAC, 230VAC, 400VAC, 24VDC, and so on. Basic Pump Control:
• Selecting a contactor with an IEC Utilization Category of AC-3 is typical for pump Three Phase DOL Starter
applications requiring starting and switching off motors during run time.
• Determine if your pump operation will require reversing of the direction, in which
case a reversing contactor will be required. in a Wastewater
• Choose the auxiliary contact based on normally open or normally closed Application
configurations.
• In addition to the above considerations, it is important to concentrate on ambient NEMA vs IEC Motor
Controls
and environment temperatures, necessity of latching, interlocking, enclosures,
overload, timers or coil surge suppressors. Understanding
IP Ratings
64
Overload Relays Industrial Control

Basics:
When used in water or wastewater industries, overload relays are governed by strict Part 1, Contactors
requirements. With so many designs available, choosing the right overload relay may
become difficult. These factors will simplify the selection process: Industrial Control
Basics: Part 2,
• Choose the overload relay that is rated for the FLA of the motor it is protecting. For
Overload Relays
example, If your FLA is 7A, then a typical bimetallic relay range would be 6.3A -
10A. Industrial Control
• Phase loss protection is another important factor to consider, as phase loss is one Basics: Part 3,
Starters
of the major causes of motor failure. Phase loss occurs when the value of one phase
is equal to zero amps due to a blown phase. When the motor remains in this phase
for a long time, it may be damaged permanently. Overload relays are designed to Motor Protection
detect the phase loss condition, therefore it is important to understand the type of Circuit Breakers
phase loss protection offered by overload relays.

Basic Pump Control:
• Other important protection factors to consider include underload, ground fault Three Phase DOL Starter
current, stall, jam, and power and voltage protection. Control of an Electric Pump

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
65
Motor Protection Circuit Breakers Industrial Control

Basics:
Most pump systems in the market today include basic motor protection built into the Part 1, Contactors
motor or control box. This protection however is designed to safeguard against only
current problems, therefore additional motor protection should be considered. There Industrial Control
are many options available to choose from, each present slightly different performance Basics: Part 2,
Overload Relays
characteristics under overload conditions. Factors to consider are:
• High fault short circuit current rating because it assures safety and reliability in
Industrial Control
extremely high fault applications. Basics: Part 3,
Starters
• Trip indication helps determine the type of maintenance or service that may be
required by identifying the cause of tripping – short circuit or overload.
• Self-protection of these devices assures excellent motor protection and helps Motor Protection
eliminate the need for additional circuit breakers and upstream fuses. Circuit Breakers
Basic Pump Control:

Applications of Motor Controls in the Water and Wastewater Industry Three Phase DOL Starter
Overload relays, contactors, and motor protection circuit breakers are largely used in
the following applications. Applying Motor Control
in a Wastewater
Application
• Influent and Effluent Pumps: The influent pumps are usually placed at the start of
the wastewater treatment plant. The wastewater first enters into the influent
NEMA vs IEC Motor
pump, which pumps it to other parts of the treatment plant. Effluent pumps are Controls
used for treating water that may contain solids up to 3/4”.
• Booster Pumps: These pumps are used for boosting the water pressure for use in Understanding
IP Ratings
light industrial and commercial applications. The booster pumps are mainly used for
potable water applications.
66
• Digested Sludge Pumps: Contaminated sludge is treated in wastewater treatment Industrial Control
Basics:
plants before being released into water bodies. The sludge contains solids which Part 1, Contactors
may block the pipeline, so special pumps are used for the purpose. Sometimes,
sludge choppers are integrated into the pumps, or submersible centrifugal pumps Industrial Control
are used for pumping fluids having high sludge content. Basics: Part 2,
Overload Relays
• Submersible Pumps: As their name suggests, these pumps are completely
submerged in the liquid. These pumps are used to drain the slurry or sewage and
Industrial Control
are mostly placed under the sewage or wastewater treatment plants. Their Basics: Part 3,
Starters
operation is controlled using advanced motors.

Applicable Standards and Compliances Motor Protection
Circuit Breakers
All motor controls referenced in this document are designed in accordance with
standards published by NEMA (National Electrical Manufacturers Association) or IEC Basic Pump Control:
(International Electrotechnical Commission).
NEMA is primarily a North American Standard, whereas IEC is a global standard.

in a Wastewater
Nema Rating Application
The NEMA ratings of a starter depend largely on the maximum horsepower ratings
NEMA vs IEC Motor
given in the National Electrical Manufacturers Association ISCS2 standard. The Controls
selection of NEMA starters is done on the basis of their NEMA size, which varies from
Size 00 to Size 9. Understanding
IP Ratings
The NEMA starter, at its stated rating, can be used for a wide range of applications,
67
which are more demanding. It is necessary to know the voltage and horsepower of Industrial Control
Basics:
the motor when selecting the proper NEMA motor starter. In the case where there is Part 1, Contactors
device will be required. Industrial Control
Basics: Part 2,
Overload Relays
00 9 1 2 Industrial Control
0 18 3 5 Basics: Part 3,
Starters
1 27 5 10
2 45 15 25
3 90 30 50 The Benefits of Type E/F
Motor Protection
4 135 50 100
Circuit Breakers
5 270 100 200
6 540 200 400
7 810 300 600 Basic Pump Control:
8 1215 450 900
9 2250 800 1600

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
68

Basics:
defined by utilization categories. As far as general motor starting applications are Basics: Part 2,
Overload Relays
concerned, AC3 and AC4 are the most common utilization categories.
Industrial Control
IEC Rating Basics: Part 3,
Utilization Category IEC Category Description Starters
AC2 Starting of slip-ring motors The Benefits of Type E/F
AC3 Starting of squirrel-cage motors and switching off only when the motor is up to speed. (Make Motor Protection
LRA, Break FLA) Circuit Breakers
AC4 Starting of squirrel-cage motors with inching and plugging duty. Rapid Start/Stop. (Make and
Break LRA) Basic Pump Control:
AC11 Auxiliary (control) circuits Three Phase DOL Starter
Unlike NEMA sizes, they are typically rated by their maximum operating current,
thermal current, HP and/or kW rating. in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
69
Pooling it all together Industrial Control

Basics:
Below are three examples of pump control, using basic industrial motor controls. These Part 1, Contactors
are simple representations, and not intended to provide complete solutions.

Industrial Control
Basics: Part 2,
Basic Pump Control Examples
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
70

Basics:
Pump stations are used to move water through the different stages of water and Part 1, Contactors
wastewater treatment. While the type of pump changes throughout the water
treatment, they all share the electric motor and a way to control that motor. Proper Industrial Control
Basics: Part 2,
pump, motor, and controls selection optimizes the efficiency of treatment and can save Overload Relays
up to 50% energy savings. Control components you want to make sure are included in
your pumping application are: contactors, overload relays, and motor protection circuit Industrial Control
breakers. These devices are designed in accordance with NEMA or IEC standards to Basics: Part 3,
Starters
meet your application needs.
Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
71
NEMA vs IEC Motor Controls
How to select the best choice for your needs Industrial Control
Basics:
Part 1, Contactors
In measuring electric motors and motor controls, there are two standards in use:
Industrial Control
the National Electrical Manufacturers Association (NEMA) and the International Basics: Part 2,
Electrotechnical Commission (IEC). Basically, NEMA vs IEC. Overload Relays
NEMA is mostly used in North America while IEC is used in most parts of the world. But Industrial Control
Basics: Part 3,
that doesn’t mean the motors used are different. In fact, NEMA and IEC motors have Starters
the same output power, efficiency, and size.
When choosing between NEMA vs IEC, the pros and cons of each can guide you. Read Motor Protection
Circuit Breakers
on to understand the differences between NEMA vs IEC and how each can suit your
intended application. Basic Pump Control:
The Background of NEMA vs IEC
For a long time, many clients have preferred to use NEMA ratings over all others. This is Applying Motor Control
in a Wastewater
because the ratings pertain to electric motors, enclosures, and motor controllers. Most Application
American-based companies require that electrical components and enclosures adhere
to NEMA standards. NEMA vs IEC Motor
Controls
Recently, IEC has found its way into the market, covering almost the same categories
as NEMA codes. The ratings were originally more specific to the Asian and European Understanding
IP Ratings
markets. As the world continued to move towards globalization, electrical designers
and engineers have had to conform to IEC standards.
72
It’s imperative that the engineering, maintenance, and service personnel are familiar Industrial Control
Basics:
with these standards. Most production equipment finding its way to the U.S. market Part 1, Contactors
from overseas must meet the IEC standards.
Industrial Control
Basics: Part 2,
What is NEMA? Overload Relays
NEMA is the National Electrical Manufacturers Association. It’s the largest trade
association of electrical equipment manufacturers in the U.S. It was founded in 1926, Industrial Control
Basics: Part 3,
to urge manufacturers to use a standard frame size for motor control and lighting Starters
applications.
Motor Protection
This would allow the standardization of parts from different manufacturers. It also sees Circuit Breakers
to it that manufacturers design components that meet the safety factors of the design
ratings. The association also dictates the configuration and performance parameters of Basic Pump Control:
electrical components. Three Phase DOL Starter
Those used in power generation, distribution, control, transmission, and end use must Applying Motor Control
comply with NEMA standards. This has been a daunting responsibility, but one which in a Wastewater
Application
NEMA has carried out with distinction all through.
NEMA vs IEC Motor

The advantages of NEMA ratings are that they’re better at withstanding short circuits. Controls
They’re also versatile and highly suitable for a wide range of applications.
Understanding
IP Ratings
What is IEC?
IEC is the International Electro-technical Commission that oversees the standards for
the European electrical communities. It was formed in 1906 and mainly focused on the 73
European market until after World War II. Industrial Control

Basics:
Part 1, Contactors
IEC-certified components are now widely being used by a growing number of
companies in North America and the U.S. Industrial Control
Basics: Part 2,
Overload Relays
The benefits of IEC-rated products are that they’re low cost, compact, and inherently
safe to the users.
Industrial Control
Basics: Part 3,
Starters
The Similarities of NEMA vs IEC
The two standards of rating have a significant similarity. This lies in the solid-state The Benefits of Type E/F
overload relay, which has evolved rapidly over the past decade. The relays have Motor Protection
Circuit Breakers
replaced both eutectic and bimetal trip mechanisms in many applications.
Basic Pump Control:
However, bimetal mechanical overload devices are still widely in use today. The Three Phase DOL Starter
difference between the solid-state overload relays used in NEMA vs IEC ratings is
minimal. Both ratings can be used on the same application, making the main difference
be the contactors and enclosure. in a Wastewater
Application
The advantages of using either NEMA or IEC controls are:

NEMA vs IEC Motor
1. Better motor protection Controls
2. Increased adjustability
3. Jam protection Understanding
IP Ratings
4. Minimized tipping
However, there are instances when each type of classification has advantages over the
other. For example, IEC is less expensive if the operating conditions are clearly defined. 74
Differentiating Between NEMA and IEC Products Industrial Control

Basics:
NEMA and IEC electromechanical products differ, but in today’s business environment, Part 1, Contactors
flexibility is essential. If users can apply IEC or NEMA-style products, they’ve got the
flexibility to adapt to product supply and local requirements. Industrial Control
Basics: Part 2,
Overload Relays
In doing so, they’ve got the benefit of local availability and expertise, which is a
competitive edge. However, to adequately apply this flexibility, you need to understand Industrial Control
the differences between NEMA and IEC designs. Basics: Part 3,
Starters
1. Different Philosophies
The philosophy upheld by NEMA emphasizes on robust designs for applicability on a Motor Protection
broader scope. The two primary fundamental mainstays within the philosophy are ease Circuit Breakers
of selection and range of application.

Basic Pump Control:
The design of NEMA motor control devices is governed by the NEMA Industrial Control Control of an Electric Pump
Standard (ICS-2). This is a formal document that contains detailed information about
the electromechanical design of NEMA motor control. Applying Motor Control
in a Wastewater
Application
On the other hand, the IEC philosophy revolves around performance and application.
IEC devices require a sophisticated level of knowledge about the equipment in NEMA vs IEC Motor
question. For example, you must understand the duty cycle, motor load, and full load Controls
current functions.
Understanding
IP Ratings
This requirement may be a drawback in some segments. In some others, it’s a
considerable advantage, especially in the Original Equipment Manufacturer sector.
75
For example, an HP-rated IEC device may be substantially smaller than a similar one Industrial Control
Basics:
from NEMA. Part 1, Contactors
This is one significant advantage for OEM designers. Besides, IEC products are less
Industrial Control
expensive. Basics: Part 2,
Overload Relays
2. Features and Benefits

Industrial Control
The design of NEMA products gives them the advantage of the ease of selection. The Basics: Part 3,
most essential features to know when choosing a NEMA product are voltage and Starters
horsepower.
Motor Protection
Most importantly, it’s essential to check the serviceability of devices in the NEMA Circuit Breakers
market. Most of the products are easy to service as they provide access to internal
parts. Apart from cases where total replacement is required; coils and contacts can be Basic Pump Control:
repaired with the device still on the panel. Control of an Electric Pump
Another consideration in the features is reserve capacity. Most of NEMA products Applying Motor Control
in a Wastewater
are robust and broadly applicable. They’re also more general purpose than their IEC
Application
counterparts.
NEMA vs IEC Motor
NEMA devices have interchangeable heater elements, with a range of units available Controls
for the overload. This is a characteristic that makes NEMA products more desirable on
most construction jobs. Understanding
IP Ratings
The Enclosed Package Solution or Motor Control Center is a well-known NEMA

tradition. Most products are sold as starters, either in open-style or enclosed versions.
76
IEC Features and Benefits Industrial Control

Basics:
Most IEC contactor sizes allow you to match the contactor to the application Part 1, Contactors
conveniently. This contrasts NEMA, where the sizes are standard across the industry.
With IEC, the contactor size ratings vary by manufacturer. Industrial Control
Basics: Part 2,
Overload Relays
Normally, an IEC starter is almost half the size of a similar NEMA starter. However,
above 100A, the physical differences are negligible. Industrial Control
Basics: Part 3,
Starters
IEC products are more flexible and modular in nature and can snap on DIN rails
up to 75mm. This removes the need to drill holes for mounting each component
individually. Putting them into a panel becomes relatively easy. Motor Protection
Circuit Breakers
IEC starters are sold as components comprising a contactor, an auxiliary block and
Basic Pump Control:
overload relay block. This way, you can assemble the parts yourself. You do this by Three Phase DOL Starter
selecting the accessories you need and snapping them together without the use of Control of an Electric Pump
tools.
in a Wastewater
IEC-style thermal overload relays come with fixed thermal elements. Their Application
adjustment range may call for the complete overload when there are changes in the
application requirements. NEMA vs IEC Motor
Controls
NEC sec. 430-53 deals with contactors that need to be applied in group applications.
Understanding
However, this isn’t unique to IEC only since other starters can be installed this way. IP Ratings
77
3. Type 2 Coordination Industrial Control

Basics:
This is an IEC standard that applies to NEMA products as well. It’s afforded by the Part 1, Contactors
use of a contactor or starter. The protection type requires the starter to be reusable
after short-circuit conditions. The IEC standards allow no significant changes in the Industrial Control
operating time-current features of the overload relay. Basics: Part 2,
Overload Relays
Since this is a coordinated protection standard, it applies to both NEMA and IEC.
Industrial Control
However, NEMA has a greater selection of short-circuit protective devices. The Basics: Part 3,
Starters
selection of fuses with IEC-style products is limited.

It’s also worth noting that IEC products are more disposable than serviceable. Most of
Motor Protection
them below 100A can’t be serviced; they are required to be removed from a DIN rail, Circuit Breakers
for replacement with a new component.
Basic Pump Control:
Self-protected starters are the representation of a new category of combination Control of an Electric Pump
starters. This kind of starter has a contactor, overload relay, and short-circuit
protection. They also undergo a unique testing procedure that goes beyond the Applying Motor Control
in a Wastewater
conventional combination of motor controls. Application
4. Training NEMA vs IEC Motor

One of the biggest differences between IEC and NEMA products is training. The design Controls
of IEC products is more application-specific. The products also require a higher level of
knowledge in the selection process. Understanding
IP Ratings
You may not need intensive training to be able to select an IEC product, but the training
has to be very specific. It calls for more time and knowledge upfront, to match the
78
selection to the application. Industrial Control

Basics:
Part 1, Contactors
5. The State of the Market
NEMA largely has its base in North America, with some presence in some parts of the Industrial Control
world. The presence is mostly in areas with large U.S. influences, like U.S. companies Basics: Part 2,
Overload Relays
based in the Middle East.
Industrial Control
Over several years, many companies have shifted from NEMA-style contactors and Basics: Part 3,
starters to IEC ones. The conversion has leveled off by market segments. Those in Starters
commercial and light industries have nearly completed the transition to IEC.
Motor Protection
Those in process industries have proactively remained with NEMA-style devices. In Circuit Breakers
terms of the number of products sold, IEC-style ones outsell NEMA-style ones. In dollar
Basic Pump Control:
value, NEMA-style devices outsell IEC products.

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
79
Other Differences Between NEMA vs IEC Industrial Control

Basics:
The primary difference between the two contactors is that NEMA provides for up to Part 1, Contactors
25% service factor. IEC, on the other hand, focuses on space and cost-savings. It tests
components to their exact design IP rating, using utilization categories to rate items Industrial Control
Basics: Part 2,
according to their intended use. Overload Relays
As such, devices that operate below 100A or 50HP are going to be much larger for Industrial Control
NEMA and more expensive. IEC will also have more options for a power rating, making Basics: Part 3,
Starters
it more critical than the NEMA ratings. This is where the contention lies in the United
States regarding the IEC system. The Benefits of Type E/F
Motor Protection
Circuit Breakers
It’s also worth noting that NEMA addresses matters to do with the construction of
electrical elements. The standards are all about minimum design requirements for
Basic Pump Control:
enclosures. IEC is more inclined towards IP ratings. Three Phase DOL Starter
NEMA addresses corrosion, something amiss with the IEC classifications. NEMA
also incorporates some level of protecting enclosures against corrosion. Sometimes, in a Wastewater
NEMA ratings and IEC’s IP ratings don’t directly correspond, since they cover different Application
protections.
NEMA vs IEC Motor
Controls
Understanding
IP Ratings
80
Comparing NEMA vs IEC Industrial Control

Basics:
When choosing between NEMA vs IEC, there are some key differences to note. Part 1, Contactors
Industrial Control
• IEC-rated equipment is less expensive than NEMA-rated ones. Basics: Part 2,
• NEMA ratings are more versatile, designed to apply to many different applications. Overload Relays
• NEMA caters to large-sized devices in North American Markets only.
• IEC ratings are for more compact devices in the global market. Industrial Control
Basics: Part 3,
• IEC ratings react faster to overloads while NEMA ratings withstand short circuits. Starters
• IEC devices are safe to the user, while NEMA devices require safety covers.
Motor Protection
Despite these significant differences, there are still some common misunderstandings Circuit Breakers
that need to be debunked. One of them is concerning the NEMA starter. Although it
looks larger than the IEC starter, some people think it makes more robust devices. Basic Pump Control:
In actuality, it merely looks more extensive because of its design. As a result, the wrong
IEC classification will be used instead of the accurate NEMA classification. This will lead Applying Motor Control
in a Wastewater
to blame on the IEC system when the rating fails to perform as expected.
Application
In reality, the Underwriters Laboratories testing applies across the board for both IEC NEMA vs IEC Motor
and NEMA applications. In essence, the differences are not merely about the sizes or Controls
cost-effectiveness. There’s a need to gain a deeper understanding of how each system
works. Understanding
IP Ratings
81
NEMA Rating Industrial Control

Basics:
The NEMA ratings of a starter depends largely on the maximum horsepower ratings Part 1, Contactors
given in the National Electrical Manufacturers Association ISCS2 standard. The
selection of the NEMA starters is done on the basis of their NEMA size, which varies Industrial Control
from Size 00 to Size 9. Basics: Part 2,
Overload Relays

Industrial Control
Basics: Part 3,
00 9 1 2 Starters
0 18 3 5
1 27 5 10
2 45 15 25
Motor Protection
3 90 30 50 Circuit Breakers
4 135 50 100
5 270 100 200
Basic Pump Control:
6 540 200 400 Three Phase DOL Starter
7 810 300 600 Control of an Electric Pump
8 1215 450 900
9 2250 800 1600
in a Wastewater
The NEMA starter, at its stated rating, can be used for a wide range of applications, Application
which are more demanding. It is necessary to know the voltage and horsepower of NEMA vs IEC Motor
Controls
the motor when selecting the proper NEMA motor starter. In the case where there is
Understanding
device will be required. IP Ratings
82

Basics:
defined by utilization categories. As far as general motor starting applications are Basics: Part 2,
Overload Relays
concerned, AC3 and AC4 are the most common utilization categories.
Industrial Control
IEC Rating Basics: Part 3,
Utilization Category IEC Category Description Starters
AC2 Starting of slip-ring motors The Benefits of Type E/F

Motor Protection
AC3 Starting of squirrel-cage motors and switching off only when the motor is up to speed. (Make
Circuit Breakers
LRA, Break FLA)
AC4 Starting of squirrel-cage motors with inching and plugging duty. Rapid Start/Stop. (Make and
Break LRA) Basic Pump Control:
AC11 Auxiliary (control) circuits
Unlike NEMA sizes, they are typically rated by their maximum operating current, Applying Motor Control
thermal current, HP and/or kW rating. in a Wastewater
Application
There are other parameters that are important to consider, while selecting motor
NEMA vs IEC Motor
starters, such as time-limit acceleration, current-line acceleration, control voltage, Controls
number of poles, and operating temperature.
Understanding
IP Ratings
83

Basics:
Mechanical and electrical, industrial applications must be tested for safety before their Part 1, Contactors
release into the market. The Ingress Protection mark differs from one rating company
to the other. However, the two primary outstanding standards are by NEMA and IEC. Industrial Control
Basics: Part 2,
Overload Relays
NEMA standards have been more popular than the IEC one. Currently, they’re
becoming more acceptable in the global market, especially for compact devices. IEC- Industrial Control
rated devices are less expensive than NEMA-rated ones. Basics: Part 3,
Starters
When choosing between NEMA and IEC rated-devices, it’s essential to understand The Benefits of Type E/F
what the rating represents. The industry has made efforts to standardize the ratings; Motor Protection
Circuit Breakers
hence, you shouldn’t expect any impactful differences.
Basic Pump Control:

One key aspect of the ratings is that they’ve helped eliminate vagueness in some Three Phase DOL Starter
commonly used terms like “waterproof.” The ratings give you a clear explanation of Control of an Electric Pump
what you can expect with each device. If you’ve got challenges interpreting the ratings
depending on a devices application, seek professional help. in a Wastewater
Application
For all your industrial control product needs, be sure to check out our shop.
NEMA vs IEC Motor
Controls
Understanding
IP Ratings
84
Understanding IP Ratings
Industrial Control
Basics:
Introduction Part 1, Contactors
Across almost every industry, there’s a need for electrical control products. From the
Industrial Control
building and construction sector to commercial retail entities, everything requires power Basics: Part 2,
to run. Overload Relays
Purchasing these components is one step, but protecting them is another. Industrial Control
Basics: Part 3,
Starters
On one side, the cables and relays themselves require protection against environmental
conditions, as they’re carrying a significant amount of electricity. Then, there are the The Benefits of Type E/F
Motor Protection
operators and controllers who need to protect themselves from accidental exposure. Circuit Breakers
It sounds simple, but in reality, this step can be challenging, even for those well-versed Basic Pump Control:
in the electrical industry. This is where the IP Ratings Chart, which details such levels of
protection, comes in.
This article takes an in depth look at the chart and breaks it down into simple categories. in a Wastewater
Application
Though this data can be complex, it’s critical to safeguarding your system and important
to learn. NEMA vs IEC Motor
Controls
Understanding
IP Ratings
86
Why is Protection Against Exposure Important? Industrial Control

Basics:
Any time someone comes into contact with energized electrical equipment, there is an Part 1, Contactors
inherent danger. One of the most common risks associated with this environment is an
arc flash. Industrial Control
Basics: Part 2,
Overload Relays
Also called a flashover, this phenomenon occurs when low impedance connections form
within an electrical system. This moves an electrical discharge through the air, which Industrial Control
can travel between voltage phases or to the ground. Basics: Part 3,
Starters
When this happens, it causes the air pressure and temperature between the electrical The Benefits of Type E/F
conductors to rise, leading to an arc blast. Temperatures soar to up to 35,000 degrees Motor Protection
Circuit Breakers
Fahrenheit in less than one-thousandth of a second and a sound wave (160-decibel or
higher) forms.
Basic Pump Control:
During the blast, molten metal and shrapnel hurl out at speeds of up to 700 miles per
hour. The event lasts mere milliseconds but can lead to death, severe burns, or hearing
loss. In fact, up to 80% of all electrical burns are arc blast-related, most of which require in a Wastewater
a hospital stay of two to four months. Application
NEMA vs IEC Motor

In addition to worker injuries, arc blasts also damage or ruin equipment and halt Controls
production.
Understanding
IP Ratings
87
Industrial Control
Electrical Industry Safety Standards and Regulations Basics:
To help mitigate these accidents, the government relies on strict industry standards Part 1, Contactors
for labeling all electrical components. For instance, under the National Electrical
Code (NEC), Article 110.16, electrical inspectors must require that all systems Industrial Control
Basics: Part 2,
include a label that details their potential incident energy associated with an arc flash Overload Relays
event.
Industrial Control
In addition, the International Electrotechnical Commission (IEC) put forth Standard Basics: Part 3,
Starters
60529. This classifies the level of protection each component offers against
accidental human contact and exposure to live parts. It also lists how protected the The Benefits of Type E/F
component is from solid parts entering into it. Motor Protection
Circuit Breakers
In this case, the grading scale is an IP rating.

Basic Pump Control:

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
88
What is the IP Ratings Chart? Industrial Control

Basics:
Short for Ingress Protection or International Protection, an IP rating details how Part 1, Contactors
protected an electrical enclosure or cabinet is from external elements, including dust,
debris, human contact, and moisture. Industrial Control
Basics: Part 2,
Overload Relays
When you’re looking for a new enclosure for your workplace, it’s vital to understand IP
ratings and know which ones are most appropriate for your environment. Industrial Control
Basics: Part 3,
Starters
For the full scope of the ratings, you can refer to international standard EN 60529
(British BS EN 60529:1992, European IEC 60509:1989). In this article, we provide an The Benefits of Type E/F
overview of what the ratings chart looks like and what it means. Motor Protection
Circuit Breakers
The International Electrotechnical Commission (IEC) established a multi-part labeling

Basic Pump Control:
system to denote how protected each component is. The IP rating includes three to Three Phase DOL Starter
four elements, including:

• The words “IP” at the beginning in a Wastewater
• A first number that describes how protected people are from the component’s Application
moving parts, along with how protected the component is from the environment
NEMA vs IEC Motor
and foreign bodies. Controls
• A second number that describes how well-protected the electrical enclosure is
from liquids and moisture, including sprays, dips, and submersions. Understanding
IP Ratings
89
What Does IPX Mean? Industrial Control

Basics:
The IEC 60529 standard grades each electrical enclosure on those two numbers listed Part 1, Contactors
above. Manufacturers will place an “X” in the place of one (or both) of the two numbers
if a particular enclosure isn’t graded for that category. Industrial Control
Basics: Part 2,
Overload Relays
Need an example?
Industrial Control
Take an electrical socket that’s rated IP2X. This rating protects it against someone Basics: Part 3,
Starters
inserting their fingers inside of it (Hence, the first “2”). However, it doesn’t require
protection against liquid, as it will function fine when exposed to vertically dripping The Benefits of Type E/F
water. Motor Protection
Circuit Breakers
As such, it’s written as IP2X, with the “2” standing for the solid protection only.
Basic Pump Control:
On the other hand, IPX2 may signify that a component has no definite protection
against foreign bodies. However, it has protection in an environment where water flows
at a 15-degree angle. in a Wastewater
Application
Likewise, a component rated IP5X can handle moderate amounts of dust but has no
NEMA vs IEC Motor
moisture protection. Controls
When you understand how to read these codes, you can ensure that your equipment Understanding
will remain in top operating condition. For instance, you wouldn’t install an electrical IP Ratings
cabinet in snowy Minnesota without first checking to make sure the components
feature an IP rating that ensures environmental protection.
90
Industrial Control
Basics:
Part 1, Contactors
Industrial Control
Basics: Part 2,
Overload Relays
Industrial Control
Basics: Part 3,
Starters

Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
91
What Do These Numbers Mean? Industrial Control

Basics:
Starting at the IP Ratings Chart and feeling like you’re back in high school calculus class Part 1, Contactors
all of a sudden? That’s normal! If you’ve never seen it before, it’s easy to get confused.
Industrial Control
Basics: Part 2,
A chart can help you break the data down into easy categories. Let’s take a look. Overload Relays
Protection from Solids Industrial Control

Basics: Part 3,
You’ll find your enclosure’s level of solids protection right after the letters “IP.” This Starters
number will range from 1 to 6, with 6 offering the strongest level of protection.
Motor Protection
If yours has a zero here, that means the component in question offers no protection
Circuit Breakers
against object contact. Here’s a breakdown of the levels, moving from 1-6.
Basic Pump Control:
Level 1: Greater Than 50mm
A large part of the body, such as a hand, can touch or graze the component. There is
no protection against direct and deliberate handling. The object must be greater than Applying Motor Control
50 millimeters. in a Wastewater
Application
Level 2: Greater Than 12mm NEMA vs IEC Motor

This rating protects against the intrusion of fingers or small objects. Each object must Controls
be less than or equal to 80mm in length and 12mm in diameter.
Understanding
Level 3: Greater Than 2.5mm IP Ratings
This rating protects against most tools and heavy-duty wires. The object must be
greater than 2.5 millimeters.
92
Level 4: Greater Than 1mm Industrial Control

Basics:
This rating protects against small tools and tiny equipment such as screws and wires. Part 1, Contactors
Each object must be greater than 1 millimeter.
Industrial Control
Level 5: Dust Protection Basics: Part 2,
Overload Relays
This rating protects against all forms of contact and most dust. While there’s no way
to prevent dust from ingressing the enclosure at this level, this step helps cut down its
Industrial Control
amounts. Basics: Part 3,
Starters
Level 6: Dust-Tight
The component is completely dust-tight. Motor Protection
Circuit Breakers
Protection from Liquids Basic Pump Control:

The second number in the IP rating describes how well-protected the electric
component is from all kinds of liquids. These levels range from 1 to 9, with protection
growing at every interval. Applying Motor Control
in a Wastewater
Application
This will come after the words “IP” and the first number (describing solids protection).
As with the first number, if there is no unique number here, you’ll place an “X”. NEMA vs IEC Motor
Controls
Level 1: Vertical Dripping Water

Understanding
A number one on the end of an IP rating protects a component against dripping water. IP Ratings
As long as the drops flow vertically, they should have no negative or harmful effect on
the system.
93
Level 2: 15-Degree Tilted Water Industrial Control

Basics:
Water doesn’t always flow straight down. If it flows at a 15-degree angle from its Part 1, Contactors
current position and there is no risk of damage or danger when it makes contact with
the component, it receives a Level 2 rating. Industrial Control
Basics: Part 2,
Overload Relays
Level 3: Spraying Water
This rating protects against water falling as a spray. It can fall at any angle up to 60
Industrial Control
degrees from its original vertical. Basics: Part 3,
Starters
Level 4: Splashing Water

This rating notes protection against splashing water. If this water comes into contact Motor Protection
with the enclosure from any direction, no damage will occur. Testers perform tests for Circuit Breakers
10 minutes with an oscillating spray to assess ingress.

Basic Pump Control:
Level 5: Low-Pressure Water Jets Control of an Electric Pump
This rating signifies that the component can handle low-pressure water jets (6.3
mm) with ease. If the enclosure gets sprayed down by a hose nozzle, for instance, it’s Applying Motor Control
in a Wastewater
protected. Application
Level 6: High-Pressure Water Jets NEMA vs IEC Motor

Controls
This component is safe against even the most powerful jets or streams of water,
including heavy seas. It can receive the impact from any direction without a negative
Understanding
effect. IP Ratings
94
Level 7: Up to 1 Meter Immersion Industrial Control

Basics:
Under defined pressure conditions, operators can submerge this component in water Part 1, Contactors
for up to 30 minutes in depths of 15cm to 1 meter.
Industrial Control
Level 8: Immersion Beyond 1 Meter Basics: Part 2,
Overload Relays
These components can handle longer immersions at greater depths with limited
ingress. Each manufacturer will set and advertise its own testing parameters.
Industrial Control
Depending on the equipment in question, other metrics tested may include Basics: Part 3,
temperature fluctuations and flow rates. Starters

Level 9: (K) High Water Pressures and Temperatures Motor Protection
This component is protected against high-pressure and high-temperature jet sprays, Circuit Breakers
steam-cleaning processes or wash-downs. This standard is most common in road

Basic Pump Control:
vehicle applications. For more information, see Standard ISO 20653:2013 Road
Vehicles - Degrees of Protection. Control of an Electric Pump

in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
95
Most Common IP Ratings Industrial Control

Basics:
You’ll see any or all of these IP ratings depending on your specific trade. However, there Part 1, Contactors
are a few that tend to appear more often than others. Let’s take a look at some labels
you’ll see on common enclosures. Industrial Control
Basics: Part 2,
Overload Relays
IP65 Rating
This IP rates as “dust-tight” and protects against jets of water. Industrial Control
Basics: Part 3,
Starters
IP68 Rating
This IP rates as “dust-tight” and protects against submersion beyond one meter. The Benefits of Type E/F
Motor Protection
Circuit Breakers
The ratings in the above list represent the most typical “waterproof” IP ratings.
Start your search here if you know your component will be around any kind of water Basic Pump Control:
regularly.
Other Ratings for Electrical Enclosures Applying Motor Control

in a Wastewater
While IP ratings are the go-to standard for electrical enclosures, they aren’t the only Application
ones. The National Electrical Manufacturers Association (NEMA) also has a protection
rating system in place. NEMA vs IEC Motor
Controls
You’ll most often see NEMA ratings on industrial equipment manufactured in North
Understanding
America. IP Ratings
As NEMA ratings map different protection characteristics than the IEC (such as
96
corrosion resistance and construction practices), the two charts aren’t a side-by-side Industrial Control
Basics:
comparison, though they do share similarities. Part 1, Contactors
The NEMA ratings range from 1 to 13. For example, you should use an electrical Industrial Control
component with a NEMA rating of 1 in an indoor environment only, to protect it from a Basics: Part 2,
Overload Relays
small amount of falling dirt.
Industrial Control
How IP Ratings Help Comparison Efforts Basics: Part 3,
Starters
Staring at two electrical components that appear so similar you’re having a difficult time
discerning which one you should pick? Keeping your use case scenario in mind, take a The Benefits of Type E/F
Motor Protection
look at the IP rating of each! Circuit Breakers
Remember, the larger the value of each digit is, the more protection the component Basic Pump Control:
receives. For instance, a component rated IP55 is better protected than one rated as
IP43.
When you’re procuring industrial electrical equipment, you’ll need to consider where in a Wastewater
Application
you plan to install it. What (and who) do you need to protect it against? Are there any
environmental considerations to keep in mind? NEMA vs IEC Motor
Controls
Armed with this knowledge, you can make an educated decision on which part is the
best-suited for the job. Understanding
IP Ratings
97
Understanding and Using the IP Ratings Chart Industrial Control

Basics:
Though we’ve managed to wrangle it and manipulate it to power our homes and rev up Part 1, Contactors
our appliances, electricity is still a powerful and wild force.
Industrial Control
Basics: Part 2,
As such, it’s important that before anyone comes into contact with it, they understand Overload Relays
what kind of environment is the safest and what conditions the specific component can
handle. The IP Ratings Chart makes this step possible. Industrial Control
Basics: Part 3,
Starters
Are you looking for electrical control products for your next project? That’s where we
come in. The Benefits of Type E/F
Motor Protection
Circuit Breakers
We’re global leaders in the industrial electrical control industry, and we’re committed
to quality at every turn. From circuit breakers to motor control to terminal blocks,
Basic Pump Control:
we’ve got it all. Three Phase DOL Starter
Browse our selection to get started and spark your next great idea today.
in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
98

Basics:
Ingress Protection (IP) Ratings protect electrical products from being damaged by Part 1, Contactors
outside contamination and people from hurting themselves. Knowing which IP Rating
you need will help you design control panels and machines that are safer and more Industrial Control
Basics: Part 2,
reliable. The amount of solids the device protects against (levels 1-6) determines the Overload Relays
number on the left of the chart, while the amount of liquid protection (levels 1-9) is on
the right. IEC and NEMA also have their own protection rating system for enclosed Industrial Control
electrical products. Two products may look the same on the outside, but when choosing Basics: Part 3,
Starters
which product to go with, look for the one with the highest ratings.
Motor Protection
Circuit Breakers
Basic Pump Control:


in a Wastewater
Application
NEMA vs IEC Motor

Controls
Understanding
IP Ratings
99
Electric Motor Control Basics
Thank you for taking the time to visit.
We hope you found our eBook on Basic Motor Control helpful.
If you have any questions or feedback about the contents in this eBook, or if you would
like help with selecting the correct motor control components for your application,
please contact us at:
724.775.7926
connect@c3controls.com
We would love to hear from you!
Disclaimer:
The content provided in this eBook is intended solely for general information purposes and is provided with the understanding that
the authors and publishers are not herein engaged in rendering engineering or other professional advice or services. The practice of
engineering is driven by site-specific circumstances unique to each project. Consequently, any use of this information should be done
only in consultation with a qualified and licensed professional who can take into account all relevant factors and desired outcomes. The
information was posted with reasonable care and attention. However, it is possible that some information is incomplete, incorrect, or
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Electric Motor Control Basics

— a compilation of our most popular white papers

18. Industrial Control Basics: Part 2, Overload Relays

29. Industrial Control Basics: Part 3, Starters

46. The Benefits of Type E/F Motor Protection Circuit Breakers

54. Applying Motor Control in a Wastewater Application

72. NEMA vs IEC Motor Controls

86. Understanding IP Ratings

Contactor Components Industrial Control

1. Coil or Electromagnet: This is the most crucial component of a contactor. The

NEMA vs IEC Motor

How the Contactor Operates Industrial Control

Basic Pump Control:

Applying Motor Control

NEMA vs IEC Motor

Different Types of Contactor Devices Industrial Control

The Benefits of Type E/F

• Single break contacts replaced with double break contacts

Applying Motor Control

NEMA vs IEC Motor

attached to the controller physically.

Basic Pump Control:

The Life Expectancy of a Contactor or Contact Life Industrial Control

NEMA vs IEC Industrial Control

NEMA (National Electrical Manufacturers Association) is the largest trade association

IEC vs NEMA Industrial Control

NEMA vs IEC Motor

Applying Motor Control

NEMA vs IEC Motor

The Benefits of Type E/F

Basic Pump Control:

Electric Motor Starter Industrial Control

The Benefits of Type E/F

Basic Pump Control:

Applying Motor Control

NEMA vs IEC Motor

Three Phase Electric Motor Industrial Control

The Benefits of Type E/F

Basic Pump Control:

Applying Motor Control

NEMA vs IEC Motor

Star Delta Electric Motor Industrial Control

The Benefits of Type E/F

Basic Pump Control:

Summary Applying Motor Control

Introduction to Motors Industrial Control

The Benefits of Type E/F

tion, excellent operating characteristics, speed regulation, and absence of commutator.

the shaft of the motor.

The Benefits of Type E/F

Basic Pump Control:

Applying Motor Control

NEMA vs IEC Motor

Squirrel Cage Induction Motors Industrial Control

What is Overload Protection? Industrial Control

Applying Motor Control

NEMA vs IEC Motor